Dodge - Ram 3500 Van - Workshop Manual - 1998 - 1998

Factory Workshop Manual Make Dodge Model Ram 3500 Van Engine and year V8-5.9L VIN Z LDC (1998) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair A power lock and Remote Keyless Entry (RKE) module is only used on high-line versions of this vehicle that are not equipped with the optional Vehicle Theft Security System (VTSS). Models equipped with the optional VTSS have the power lock and RKE functions controlled by the Central Timer Module (CTM). See Power Lock System and Remote Keyless Entry System in the General Information for more information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the engine cover from the passenger compartment. Power Lock And Remote Keyless Entry Module Remove/Install 3. Remove the two screws that secure the power lock and RKE module to the inboard side of the left center instrument panel support. 4. Pull the power lock and RKE module away from its mounting location far enough to access and unplug the two wire harness connectors. 5. Remove the power lock and RKE module from the instrument panel. 6. Reverse the removal procedures to install. Tighten the mounting screws to 3.3 N.m (30 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair A power lock and Remote Keyless Entry (RKE) module is only used on high-line versions of this vehicle that are not equipped with the optional Vehicle Theft Security System (VTSS). Models equipped with the optional VTSS have the power lock and RKE functions controlled by the Central Timer Module (CTM). See Power Lock System and Remote Keyless Entry System in the General Information for more information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the engine cover from the passenger compartment. Power Lock And Remote Keyless Entry Module Remove/Install 3. Remove the two screws that secure the power lock and RKE module to the inboard side of the left center instrument panel support. 4. Pull the power lock and RKE module away from its mounting location far enough to access and unplug the two wire harness connectors. 5. Remove the power lock and RKE module from the instrument panel. 6. Reverse the removal procedures to install. Tighten the mounting screws to 3.3 N.m (30 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Testing and Inspection Power Door Lock Control Module: Testing and Inspection The power lock and Remote Keyless Entry (RKE) module is used on models that are not equipped with the optional Vehicle Theft Security System (VTSS). 1. Check the fused B(+) fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Check the fused ignition switch output fuse in the junction block. If OK, go to Step 5. If not OK, rep air the shorted circuit or component as required and replace the faulty fuse. 4. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output fuse in the junction block. If OK, turn the ignition switch to the Off position and go to Step 6. If not OK, repair the open circuit to the ignition switch as required. 5. Disconnect and isolate the battery negative cable. Access and unplug the power lock and RKE module wire harness connectors. See Power Lock and Remote Keyless Entry Module in the Removal and Installation for the procedures. 6. Check the wire harness connectors and the receptacles in the power lock and RKE module for loose, corroded, or damaged terminals and pins. If OK, go to Step 8. If not OK, repair the connections as required. 7. Probe the ground circuit cavity in the black power lock and RKE module wire harness connector and check for continuity to a good ground. There should be continuity. If OK, go to Step 9. If not OK, repair the open circuit to ground as required. 8. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity in the black power lock and RKE module wire harness connector. If OK, go to Step 10. If not OK, repair the open circuit to the fuse in the junction block as required. 9. Probe the door lock switch output (lock) circuit cavity in the black power lock and RKE module wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 11. If not OK, repair the open circuit from either or both power lock switch(s) to the power lock and RKE module as required. 10. Probe the door lock switch output (unlock) circuit cavity in the black power lock and RKE module wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 12. If not OK, repair the open circuit from either or both power lock switch(s) to the power lock and RKE module as required. 11. Check for continuity between the door jamb switch sense circuit cavity of the black power lock and RKE module wire harness connector and a good ground. There should be no continuity with both the side and the rear cargo doors closed, and there should be continuity with any of the side or rear cargo doors opened. Test each of the side and the rear doors. If OK, go to Step 13. If not OK, repair the open circuit to the door jamb switch(s) or replace the faulty door jamb switch(s) as required. 12. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity in the blue power lock and RKE module wire harness connector. If OK, turn the ignition switch to the Off position and go to Step 14. If not OK, repair the open circuit to the fuse in the junction block as required. 13. Plug the wire harness connectors back into the power lock and RKE module. Back probe the door latch switch sense circuit cavity of the black power lock and RKE module wire harness connector and check for continuity to a good ground. There should be no continuity. Press and release the Unlock button of the RKE transmitter. There should now be continuity for about thirty seconds. If OK, go to Step 15. If not OK, replace the faulty power lock and RKE module. 14. Back probe the door lock driver circuit cavity in the black power lock and RKE module wire harness connector and check for battery voltage as the power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the RKE transmitter. If OK, go to Step 16. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty power lock and RKE module. 15. Still back probing the door lock driver circuit cavity in the black power lock and RKE module wire harness connector, open the side or rear cargo door. Move the power lock switch to the Lock position or press the Lock button of the RKE transmitter. Now close all of the doors. Within five seconds of the last door closing, there should be battery voltage on the door lock driver circuit. If OK, go to Step 17. If not OK, replace the faulty power lock and RKE module. 16. Back probe the door unlock driver circuit cavity in the black power lock and RKE module wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter. If OK, see Power Lock Motor in the Diagnosis and Testing. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty power lock and RKE module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Testing and Inspection > Page 14 Power Door Lock Control Module: Service and Repair A power lock and Remote Keyless Entry (RKE) module is only used on high-line versions of this vehicle that are not equipped with the optional Vehicle Theft Security System (VTSS). Models equipped with the optional VTSS have the power lock and RKE functions controlled by the Central Timer Module (CTM). See Power Lock System and Remote Keyless Entry System in the General Information for more information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the engine cover from the passenger compartment. Power Lock And Remote Keyless Entry Module Remove/Install 3. Remove the two screws that secure the power lock and RKE module to the inboard side of the left center instrument panel support. 4. Pull the power lock and RKE module away from its mounting location far enough to access and unplug the two wire harness connectors. 5. Remove the power lock and RKE module from the instrument panel. 6. Reverse the removal procedures to install. Tighten the mounting screws to 3.3 N.m (30 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion Technical Service Bulletin # D20 Date: 040901 Recall - ABS Wiring Corrosion September 2004 Dealer Service Instructions for: Safety Recall D20 - ABS Wiring Corrosion Models 1998-2003 (AB) Dodge Ram Van/Wagon NOTE: This recall applies only to the above vehicles equipped with a 4-wheel Anti-lock Brake System (ABS) (sales code BGK). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject Electrolyte (battery acid) from aftermarket batteries may leak onto an Antilock Brake System (ABS) wiring connector on about 43,000 of the above vehicles. This may cause the wiring to corrode and short circuit, which can result in an underhood fire. Repair All vehicles must have a revised battery tray installed that will protect the ABS control module wiring harness connector from future electrolyte leakage. A cowl seal extension must also be installed on all vehicles to redirect any water draining from the windshield away from the battery. The ABS control module wiring harness and connector must be inspected for electrolyte damage and repaired if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 24 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 25 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 26 Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Install Cowl Seal Extension 1. Open the hood. 2. Using Mopar glass cleaner and a shop cloth, clean the plastic cowl panel where the cowl seal ends on the driver's side of the vehicle (Figure 1). 3. Test fit the cowl seal extension. Cut the cowl seal extension length so that the seal stops at the end of the plastic cowl panel (Figure 1). 4. Insert the cowl seal connector halfway into the cowl seal extension (Figure 2). 5. Remove the protective plastic covering from the glue strip on the cowl seal extension. 6. Install the cowl seal extension connector into the original cowl seal end and firmly press the seal against the plastic cowl panel (Figure 2). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 27 7. Continue with Section B. Inspect ABS Control Module Wiring Harness Connector. B. Inspect ABS Control Module Wiring Harness Connector 1. Turn the ignition switch to the "Off" position. Be certain that all electrical accessories are turned off. 2. Loosen the battery negative cable clamp pinch-bolt hex nut. 3. Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 4. Loosen the battery positive cable terminal clamp pinch-bolt hex nut. 5. Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 6. Remove the two nuts with washers that secure the battery hold down strap to the threaded end of the J-bolt and the long stud (Figure 4). 7. Remove the battery hold down strap from the top of the battery (Figure 4). 8. Remove the J-bolt from the holes in the battery tray support on the inboard side of the battery tray (Figure 4). 9. Carefully remove the battery from the battery tray. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 28 WARNING: Wear a suitable pair of rubber gloves when removing the battery. Safety glasses should also be worn. 10. Remove the three screws that secure the bottom of the battery tray to the battery tray support (Figure 5). 11. Remove the two screws that secure the outboard side of the battery tray to the left cowl side panel (Figure 5). 12. Lift the battery tray slightly and disconnect the battery temperature sensor electrical connector. 13. Remove the battery tray and the drain tube from the vehicle as an assembly (Figure 5). 14. In the area below the battery location, inspect the front (large) wiring harness connector on the ABS control module for acid damage, by spraying the connector and surrounding area with the provided Electrolyte Detection and Neutralizing Spray (Figure 6). > If the spray remains an orange color, there is no electrolyte (battery acid) on the ABS control module wiring harness connector. Continue with Section E - Battery Tray Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 29 > If the spray turns a purple color, continue with Step 15 of this procedure. 15. Disconnect the large ABS control module wiring harness connector from the ABS control module by first sliding the red lock tab forward. Then push down on the black release tab while pulling the connector from the module (Figure 7). 16. Inspect the large ABS control module wiring harness connector: a. If a heat damaged (melted) connector is found, replace the wiring harness connector. Continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no heat damage is found continue with inspection Step b. b. Inspect the wire side and the terminal side of the large ABS control module wiring harness connector for green colored corrosion. If green colored corrosion is found in one or more of the connector cavities continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no green colored corrosion is found, continue with inspection Step c. c. Looking into the terminal side of the large ABS control module wiring harness connector, inspect the metal terminals for a dull finish or discoloration. If a dull finish or discoloration is found, continue with Section C - ABS Control Module Wiring Harness Connector Replacement because the original connector housing wire weather seals have been damaged. If no dull or discolored terminals are found continue with Section E - Battery Tray Installation. C. ABS Control Module Wiring Harness Connector Replacement NOTE: Only ABS control module wiring harness connectors with heat damage (melted), green wire terminals or dull/discolored terminals, as determined by the inspection in Section B, require replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 30 1. Remove the secondary terminal lock from the original ABS control module wiring harness connector housing (Figure 8). 2. Some models may have two empty wire cavities in the ABS control module wiring harness connector housing. Insert the gray wire cavity plugs supplied with the repair kit into the correct cavities of the new ABS control module wiring harness connector. 3. The ABS control module wiring harness connector terminals that do not have heat damage, green corrosion or are only dull or discolored can be transferred to the new connector using the following process: a. From the terminal side of the connector, insert a small pick into the connector next to the terminal and push on the terminal release arm while pulling on the wire. CAUTION: Remove only one wire from the original connector at a time and note which connector cavity the wire is to be transfer into. b. Using the electrolyte detection and neutralizing spray, lightly spray the removed wire until the spray remains an orange color. This may require two or three applications. c. Using compressed air, carefully dry the terminal and wire. d. Insert the terminal into the proper connector cavity of the new connector housing. e. Repeat Steps a. through d. on all wires that need to be transferred to the new connector housing. 4. The ABS control module wiring harness connector terminals with heat damage and/or green corrosion must be replaced using the following process: a. Cut off the wire one inch back from the original ABS connector. b. Remove one-half (1/2) inch (13 mm) of insulation from the wire on the harness that needs to be spliced. c. Cut the replacement wire supplied in the connector repair kit to the required length. Then remove one-half (1/2) inch (13 mm) of insulation from the wire. d. Place a piece of sealant lined heat shrink tubing on one side of the wire. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 31 e. Place the strands of wire overlapping each other inside of the brass splice band (Figure 9). f. Using crimp tool (Mopar P/N 05019912AA), crimp the brass splice band and wires together (Figure 10). g. Solder the connection together using rosin core type solder. DO NOT use acid core solder. CAUTION: All splices must be properly soldered. Failure to properly solder these wiring connectors can cause the ABS to become inoperative in the future. h. Center the shrink tubing over the splice joint. Using a heat gun, heat the surface of the shrink tubing until the shrink tubing is tightly sealed and sealant comes out of both ends of the shrink tubing (Figure 11). 5. After all of the terminals have been transferred or replaced, install the blue secondary terminal lock into the ABS control module wiring harness connector (Figure 8). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 32 6. Using a small mirror (Snap-on GA295 or equivalent), inspect the ABS control module connector pins for green corrosion and the connector housing for heat damage (Figure 12). > ABS control module connectors found with green corroded pins continue with Section D - ABS Control Module Replacement. > ABS control module connector housings found with heat damage continue with Section D - ABS Control Module Replacement. > ABS control module connectors found without heat damage or green corroded pins continue with Section E - Battery Tray Installation. D. ABS Control Module Replacement NOTE: Only ABS control modules with a heat damaged (melted) connector or green corroded connector pins, as determined by the inspection in Section B and C, require replacement. Very few vehicles are expected to require ABS control module replacement. 1. Disconnect the small ABS control module wiring connector from the ABS control module (Figure 13). 2. Remove the four mounting screws on the ABS control module (Figure 13). 3. Lift the module from the ABS hydraulic control unit and disconnect the solenoid connector located on the bottom side of the ABS control module. 4. Remove the ABS control module from the vehicle and discard. 5. Using a clean shop towel, clean the ABS control module mounting surface on the ABS hydraulic control unit. 6. Connect the solenoid connector to the new ABS control module and then place the module into position on the ABS hydraulic control unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 33 7. Install the four ABS control module mounting screws. Tighten the screws to 39 in. lbs (4.4 N.m). 8. Continue with Section E - Battery Tray Installation. E. Battery Tray Installation 1. If disconnected, spray the ABS control module connector and the ABS control module wiring harness connector with Electrolyte Detection and Neutralizing spray to ensure that all traces of acid have been neutralized. NOTE: When the spray remains an orange color, any remaining battery acid has been neutralized. 2. Using compressed air, carefully blow out the connector until completely dry. 3. If previously disconnected, connect the large and/or small wiring harness connectors to the ABS control module. 4. Transfer the battery temperature sensor from the old battery tray to the new battery tray (Figure 14). Then discard the old battery tray. 5. Place a small bead of RTV silicone rubber adhesive (P/N 04883971) onto the base of the new drain tube grommet. 6. Snap the new drain tube into position on the new battery tray (Figure 14). 7. While installing the new battery tray into position, route the drain tube through the original hole in the fender panel (Figure 15) and connect the battery temperature sensor electrical connector. 8. Install the battery tray mounting bolts. Tighten the bolts to 95 in. lbs. (10.7 N.m). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 34 9. Install the battery onto the new battery tray. 10. Install the "J" hook and battery hold down bracket. 11. Install the battery hold down retaining nuts. Tighten the nuts to 24 in. lbs. (2.7 N.m). 12. Connect the positive battery cable to the positive battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 13. Connect the negative battery cable to the negative battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 14. From inside the left wheel well housing, secure the battery tray drain tube to the frame rail bracket with the provided plastic tie strap (Figure 16). 15. If the ABS control module was replaced, connect the DRB III scan tool to the vehicle and program the rear axle ratio and tire size into the new control module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 35 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA04V185000 > Apr > 04 > Recall 04V185000: ABS Control Module Corrosion Electronic Brake Control Module: Recalls Recall 04V185000: ABS Control Module Corrosion DEFECT: On some van and wagon model vehicles equipped with 4-wheel antilock brake systems (ABS), aftermarket batteries may leak electrolyte onto the ABS control module connector, which can compromise the sealing integrity of the connector. This may allow development of a short circuit in the connector, which could eventually lead to a fire. REMEDY: Dealers will inspect the ABS control module connector for electrolyte damage and replace the connector as necessary. The manufacturer has not yet provided an owner notification for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-002-02 > Jan > 02 > Rear Axle - Vehicle Speed Is Inaccurate Electronic Brake Control Module: Customer Interest Rear Axle - Vehicle Speed Is Inaccurate NUMBER: 18-002-02 GROUP: Vehicle Performance DATE: January 21, 2002 THE MDS2(R) MUST BE OPERATING WITH CIS CD2094 OR HIGHER, AVAILABLE OCTOBER 29, 2001. THE DRBIII(R) MUST BE AT LEVEL 52.5 OR LATER. SUBJECT: Pinion Factor Recalibration MODELS: 1998-2002 AB Ram Van NOTE: THIS BULLETIN APPLIES TO ALL 1998 - 2002 (AB) RAM VANS EQUIPPED WITH THE 9.25 REAR AXLE. DISCUSSION: Owners of 1998 - 2002 (AB) Ram Vans equipped with the 9.25 rear axle may complain that vehicle speed is inaccurate. It may be that past service on the rear axle has caused the calibration to change. Accurate calibration can be restored by reprogramming the applicable module, (ABS) Antilock Brake System or (RWAL) Rear Wheel Antilock, using the DRBI III(R). NOTE: THE DRBIII(R) MUST BE AT LEVEL 52.5 OR HIGHER AND THE MDSII(R) AT CD 2094 OR HIGHER TO PERFORM THE REPROGRAMMING. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion Technical Service Bulletin # D20 Date: 040901 Recall - ABS Wiring Corrosion September 2004 Dealer Service Instructions for: Safety Recall D20 - ABS Wiring Corrosion Models 1998-2003 (AB) Dodge Ram Van/Wagon NOTE: This recall applies only to the above vehicles equipped with a 4-wheel Anti-lock Brake System (ABS) (sales code BGK). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject Electrolyte (battery acid) from aftermarket batteries may leak onto an Antilock Brake System (ABS) wiring connector on about 43,000 of the above vehicles. This may cause the wiring to corrode and short circuit, which can result in an underhood fire. Repair All vehicles must have a revised battery tray installed that will protect the ABS control module wiring harness connector from future electrolyte leakage. A cowl seal extension must also be installed on all vehicles to redirect any water draining from the windshield away from the battery. The ABS control module wiring harness and connector must be inspected for electrolyte damage and repaired if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 50 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 51 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 52 Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Install Cowl Seal Extension 1. Open the hood. 2. Using Mopar glass cleaner and a shop cloth, clean the plastic cowl panel where the cowl seal ends on the driver's side of the vehicle (Figure 1). 3. Test fit the cowl seal extension. Cut the cowl seal extension length so that the seal stops at the end of the plastic cowl panel (Figure 1). 4. Insert the cowl seal connector halfway into the cowl seal extension (Figure 2). 5. Remove the protective plastic covering from the glue strip on the cowl seal extension. 6. Install the cowl seal extension connector into the original cowl seal end and firmly press the seal against the plastic cowl panel (Figure 2). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 53 7. Continue with Section B. Inspect ABS Control Module Wiring Harness Connector. B. Inspect ABS Control Module Wiring Harness Connector 1. Turn the ignition switch to the "Off" position. Be certain that all electrical accessories are turned off. 2. Loosen the battery negative cable clamp pinch-bolt hex nut. 3. Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 4. Loosen the battery positive cable terminal clamp pinch-bolt hex nut. 5. Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 6. Remove the two nuts with washers that secure the battery hold down strap to the threaded end of the J-bolt and the long stud (Figure 4). 7. Remove the battery hold down strap from the top of the battery (Figure 4). 8. Remove the J-bolt from the holes in the battery tray support on the inboard side of the battery tray (Figure 4). 9. Carefully remove the battery from the battery tray. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 54 WARNING: Wear a suitable pair of rubber gloves when removing the battery. Safety glasses should also be worn. 10. Remove the three screws that secure the bottom of the battery tray to the battery tray support (Figure 5). 11. Remove the two screws that secure the outboard side of the battery tray to the left cowl side panel (Figure 5). 12. Lift the battery tray slightly and disconnect the battery temperature sensor electrical connector. 13. Remove the battery tray and the drain tube from the vehicle as an assembly (Figure 5). 14. In the area below the battery location, inspect the front (large) wiring harness connector on the ABS control module for acid damage, by spraying the connector and surrounding area with the provided Electrolyte Detection and Neutralizing Spray (Figure 6). > If the spray remains an orange color, there is no electrolyte (battery acid) on the ABS control module wiring harness connector. Continue with Section E - Battery Tray Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 55 > If the spray turns a purple color, continue with Step 15 of this procedure. 15. Disconnect the large ABS control module wiring harness connector from the ABS control module by first sliding the red lock tab forward. Then push down on the black release tab while pulling the connector from the module (Figure 7). 16. Inspect the large ABS control module wiring harness connector: a. If a heat damaged (melted) connector is found, replace the wiring harness connector. Continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no heat damage is found continue with inspection Step b. b. Inspect the wire side and the terminal side of the large ABS control module wiring harness connector for green colored corrosion. If green colored corrosion is found in one or more of the connector cavities continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no green colored corrosion is found, continue with inspection Step c. c. Looking into the terminal side of the large ABS control module wiring harness connector, inspect the metal terminals for a dull finish or discoloration. If a dull finish or discoloration is found, continue with Section C - ABS Control Module Wiring Harness Connector Replacement because the original connector housing wire weather seals have been damaged. If no dull or discolored terminals are found continue with Section E - Battery Tray Installation. C. ABS Control Module Wiring Harness Connector Replacement NOTE: Only ABS control module wiring harness connectors with heat damage (melted), green wire terminals or dull/discolored terminals, as determined by the inspection in Section B, require replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 56 1. Remove the secondary terminal lock from the original ABS control module wiring harness connector housing (Figure 8). 2. Some models may have two empty wire cavities in the ABS control module wiring harness connector housing. Insert the gray wire cavity plugs supplied with the repair kit into the correct cavities of the new ABS control module wiring harness connector. 3. The ABS control module wiring harness connector terminals that do not have heat damage, green corrosion or are only dull or discolored can be transferred to the new connector using the following process: a. From the terminal side of the connector, insert a small pick into the connector next to the terminal and push on the terminal release arm while pulling on the wire. CAUTION: Remove only one wire from the original connector at a time and note which connector cavity the wire is to be transfer into. b. Using the electrolyte detection and neutralizing spray, lightly spray the removed wire until the spray remains an orange color. This may require two or three applications. c. Using compressed air, carefully dry the terminal and wire. d. Insert the terminal into the proper connector cavity of the new connector housing. e. Repeat Steps a. through d. on all wires that need to be transferred to the new connector housing. 4. The ABS control module wiring harness connector terminals with heat damage and/or green corrosion must be replaced using the following process: a. Cut off the wire one inch back from the original ABS connector. b. Remove one-half (1/2) inch (13 mm) of insulation from the wire on the harness that needs to be spliced. c. Cut the replacement wire supplied in the connector repair kit to the required length. Then remove one-half (1/2) inch (13 mm) of insulation from the wire. d. Place a piece of sealant lined heat shrink tubing on one side of the wire. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 57 e. Place the strands of wire overlapping each other inside of the brass splice band (Figure 9). f. Using crimp tool (Mopar P/N 05019912AA), crimp the brass splice band and wires together (Figure 10). g. Solder the connection together using rosin core type solder. DO NOT use acid core solder. CAUTION: All splices must be properly soldered. Failure to properly solder these wiring connectors can cause the ABS to become inoperative in the future. h. Center the shrink tubing over the splice joint. Using a heat gun, heat the surface of the shrink tubing until the shrink tubing is tightly sealed and sealant comes out of both ends of the shrink tubing (Figure 11). 5. After all of the terminals have been transferred or replaced, install the blue secondary terminal lock into the ABS control module wiring harness connector (Figure 8). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 58 6. Using a small mirror (Snap-on GA295 or equivalent), inspect the ABS control module connector pins for green corrosion and the connector housing for heat damage (Figure 12). > ABS control module connectors found with green corroded pins continue with Section D - ABS Control Module Replacement. > ABS control module connector housings found with heat damage continue with Section D - ABS Control Module Replacement. > ABS control module connectors found without heat damage or green corroded pins continue with Section E - Battery Tray Installation. D. ABS Control Module Replacement NOTE: Only ABS control modules with a heat damaged (melted) connector or green corroded connector pins, as determined by the inspection in Section B and C, require replacement. Very few vehicles are expected to require ABS control module replacement. 1. Disconnect the small ABS control module wiring connector from the ABS control module (Figure 13). 2. Remove the four mounting screws on the ABS control module (Figure 13). 3. Lift the module from the ABS hydraulic control unit and disconnect the solenoid connector located on the bottom side of the ABS control module. 4. Remove the ABS control module from the vehicle and discard. 5. Using a clean shop towel, clean the ABS control module mounting surface on the ABS hydraulic control unit. 6. Connect the solenoid connector to the new ABS control module and then place the module into position on the ABS hydraulic control unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 59 7. Install the four ABS control module mounting screws. Tighten the screws to 39 in. lbs (4.4 N.m). 8. Continue with Section E - Battery Tray Installation. E. Battery Tray Installation 1. If disconnected, spray the ABS control module connector and the ABS control module wiring harness connector with Electrolyte Detection and Neutralizing spray to ensure that all traces of acid have been neutralized. NOTE: When the spray remains an orange color, any remaining battery acid has been neutralized. 2. Using compressed air, carefully blow out the connector until completely dry. 3. If previously disconnected, connect the large and/or small wiring harness connectors to the ABS control module. 4. Transfer the battery temperature sensor from the old battery tray to the new battery tray (Figure 14). Then discard the old battery tray. 5. Place a small bead of RTV silicone rubber adhesive (P/N 04883971) onto the base of the new drain tube grommet. 6. Snap the new drain tube into position on the new battery tray (Figure 14). 7. While installing the new battery tray into position, route the drain tube through the original hole in the fender panel (Figure 15) and connect the battery temperature sensor electrical connector. 8. Install the battery tray mounting bolts. Tighten the bolts to 95 in. lbs. (10.7 N.m). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 60 9. Install the battery onto the new battery tray. 10. Install the "J" hook and battery hold down bracket. 11. Install the battery hold down retaining nuts. Tighten the nuts to 24 in. lbs. (2.7 N.m). 12. Connect the positive battery cable to the positive battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 13. Connect the negative battery cable to the negative battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 14. From inside the left wheel well housing, secure the battery tray drain tube to the frame rail bracket with the provided plastic tie strap (Figure 16). 15. If the ABS control module was replaced, connect the DRB III scan tool to the vehicle and program the rear axle ratio and tire size into the new control module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 61 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > NHTSA04V185000 > Apr > 04 > Recall 04V185000: ABS Control Module Corrosion Electronic Brake Control Module: All Technical Service Bulletins Recall 04V185000: ABS Control Module Corrosion DEFECT: On some van and wagon model vehicles equipped with 4-wheel antilock brake systems (ABS), aftermarket batteries may leak electrolyte onto the ABS control module connector, which can compromise the sealing integrity of the connector. This may allow development of a short circuit in the connector, which could eventually lead to a fire. REMEDY: Dealers will inspect the ABS control module connector for electrolyte damage and replace the connector as necessary. The manufacturer has not yet provided an owner notification for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 18-002-02 > Jan > 02 > Rear Axle - Vehicle Speed Is Inaccurate Electronic Brake Control Module: All Technical Service Bulletins Rear Axle - Vehicle Speed Is Inaccurate NUMBER: 18-002-02 GROUP: Vehicle Performance DATE: January 21, 2002 THE MDS2(R) MUST BE OPERATING WITH CIS CD2094 OR HIGHER, AVAILABLE OCTOBER 29, 2001. THE DRBIII(R) MUST BE AT LEVEL 52.5 OR LATER. SUBJECT: Pinion Factor Recalibration MODELS: 1998-2002 AB Ram Van NOTE: THIS BULLETIN APPLIES TO ALL 1998 - 2002 (AB) RAM VANS EQUIPPED WITH THE 9.25 REAR AXLE. DISCUSSION: Owners of 1998 - 2002 (AB) Ram Vans equipped with the 9.25 rear axle may complain that vehicle speed is inaccurate. It may be that past service on the rear axle has caused the calibration to change. Accurate calibration can be restored by reprogramming the applicable module, (ABS) Antilock Brake System or (RWAL) Rear Wheel Antilock, using the DRBI III(R). NOTE: THE DRBIII(R) MUST BE AT LEVEL 52.5 OR HIGHER AND THE MDSII(R) AT CD 2094 OR HIGHER TO PERFORM THE REPROGRAMMING. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 18-002-02 > Jan > 02 > Rear Axle - Vehicle Speed Is Inaccurate Electronic Brake Control Module: All Technical Service Bulletins Rear Axle - Vehicle Speed Is Inaccurate NUMBER: 18-002-02 GROUP: Vehicle Performance DATE: January 21, 2002 THE MDS2(R) MUST BE OPERATING WITH CIS CD2094 OR HIGHER, AVAILABLE OCTOBER 29, 2001. THE DRBIII(R) MUST BE AT LEVEL 52.5 OR LATER. SUBJECT: Pinion Factor Recalibration MODELS: 1998-2002 AB Ram Van NOTE: THIS BULLETIN APPLIES TO ALL 1998 - 2002 (AB) RAM VANS EQUIPPED WITH THE 9.25 REAR AXLE. DISCUSSION: Owners of 1998 - 2002 (AB) Ram Vans equipped with the 9.25 rear axle may complain that vehicle speed is inaccurate. It may be that past service on the rear axle has caused the calibration to change. Accurate calibration can be restored by reprogramming the applicable module, (ABS) Antilock Brake System or (RWAL) Rear Wheel Antilock, using the DRBI III(R). NOTE: THE DRBIII(R) MUST BE AT LEVEL 52.5 OR HIGHER AND THE MDSII(R) AT CD 2094 OR HIGHER TO PERFORM THE REPROGRAMMING. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion Technical Service Bulletin # D20 Date: 040901 Recall - ABS Wiring Corrosion September 2004 Dealer Service Instructions for: Safety Recall D20 - ABS Wiring Corrosion Models 1998-2003 (AB) Dodge Ram Van/Wagon NOTE: This recall applies only to the above vehicles equipped with a 4-wheel Anti-lock Brake System (ABS) (sales code BGK). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject Electrolyte (battery acid) from aftermarket batteries may leak onto an Antilock Brake System (ABS) wiring connector on about 43,000 of the above vehicles. This may cause the wiring to corrode and short circuit, which can result in an underhood fire. Repair All vehicles must have a revised battery tray installed that will protect the ABS control module wiring harness connector from future electrolyte leakage. A cowl seal extension must also be installed on all vehicles to redirect any water draining from the windshield away from the battery. The ABS control module wiring harness and connector must be inspected for electrolyte damage and repaired if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 80 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 81 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 82 Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Install Cowl Seal Extension 1. Open the hood. 2. Using Mopar glass cleaner and a shop cloth, clean the plastic cowl panel where the cowl seal ends on the driver's side of the vehicle (Figure 1). 3. Test fit the cowl seal extension. Cut the cowl seal extension length so that the seal stops at the end of the plastic cowl panel (Figure 1). 4. Insert the cowl seal connector halfway into the cowl seal extension (Figure 2). 5. Remove the protective plastic covering from the glue strip on the cowl seal extension. 6. Install the cowl seal extension connector into the original cowl seal end and firmly press the seal against the plastic cowl panel (Figure 2). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 83 7. Continue with Section B. Inspect ABS Control Module Wiring Harness Connector. B. Inspect ABS Control Module Wiring Harness Connector 1. Turn the ignition switch to the "Off" position. Be certain that all electrical accessories are turned off. 2. Loosen the battery negative cable clamp pinch-bolt hex nut. 3. Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 4. Loosen the battery positive cable terminal clamp pinch-bolt hex nut. 5. Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 6. Remove the two nuts with washers that secure the battery hold down strap to the threaded end of the J-bolt and the long stud (Figure 4). 7. Remove the battery hold down strap from the top of the battery (Figure 4). 8. Remove the J-bolt from the holes in the battery tray support on the inboard side of the battery tray (Figure 4). 9. Carefully remove the battery from the battery tray. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 84 WARNING: Wear a suitable pair of rubber gloves when removing the battery. Safety glasses should also be worn. 10. Remove the three screws that secure the bottom of the battery tray to the battery tray support (Figure 5). 11. Remove the two screws that secure the outboard side of the battery tray to the left cowl side panel (Figure 5). 12. Lift the battery tray slightly and disconnect the battery temperature sensor electrical connector. 13. Remove the battery tray and the drain tube from the vehicle as an assembly (Figure 5). 14. In the area below the battery location, inspect the front (large) wiring harness connector on the ABS control module for acid damage, by spraying the connector and surrounding area with the provided Electrolyte Detection and Neutralizing Spray (Figure 6). > If the spray remains an orange color, there is no electrolyte (battery acid) on the ABS control module wiring harness connector. Continue with Section E - Battery Tray Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 85 > If the spray turns a purple color, continue with Step 15 of this procedure. 15. Disconnect the large ABS control module wiring harness connector from the ABS control module by first sliding the red lock tab forward. Then push down on the black release tab while pulling the connector from the module (Figure 7). 16. Inspect the large ABS control module wiring harness connector: a. If a heat damaged (melted) connector is found, replace the wiring harness connector. Continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no heat damage is found continue with inspection Step b. b. Inspect the wire side and the terminal side of the large ABS control module wiring harness connector for green colored corrosion. If green colored corrosion is found in one or more of the connector cavities continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no green colored corrosion is found, continue with inspection Step c. c. Looking into the terminal side of the large ABS control module wiring harness connector, inspect the metal terminals for a dull finish or discoloration. If a dull finish or discoloration is found, continue with Section C - ABS Control Module Wiring Harness Connector Replacement because the original connector housing wire weather seals have been damaged. If no dull or discolored terminals are found continue with Section E - Battery Tray Installation. C. ABS Control Module Wiring Harness Connector Replacement NOTE: Only ABS control module wiring harness connectors with heat damage (melted), green wire terminals or dull/discolored terminals, as determined by the inspection in Section B, require replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 86 1. Remove the secondary terminal lock from the original ABS control module wiring harness connector housing (Figure 8). 2. Some models may have two empty wire cavities in the ABS control module wiring harness connector housing. Insert the gray wire cavity plugs supplied with the repair kit into the correct cavities of the new ABS control module wiring harness connector. 3. The ABS control module wiring harness connector terminals that do not have heat damage, green corrosion or are only dull or discolored can be transferred to the new connector using the following process: a. From the terminal side of the connector, insert a small pick into the connector next to the terminal and push on the terminal release arm while pulling on the wire. CAUTION: Remove only one wire from the original connector at a time and note which connector cavity the wire is to be transfer into. b. Using the electrolyte detection and neutralizing spray, lightly spray the removed wire until the spray remains an orange color. This may require two or three applications. c. Using compressed air, carefully dry the terminal and wire. d. Insert the terminal into the proper connector cavity of the new connector housing. e. Repeat Steps a. through d. on all wires that need to be transferred to the new connector housing. 4. The ABS control module wiring harness connector terminals with heat damage and/or green corrosion must be replaced using the following process: a. Cut off the wire one inch back from the original ABS connector. b. Remove one-half (1/2) inch (13 mm) of insulation from the wire on the harness that needs to be spliced. c. Cut the replacement wire supplied in the connector repair kit to the required length. Then remove one-half (1/2) inch (13 mm) of insulation from the wire. d. Place a piece of sealant lined heat shrink tubing on one side of the wire. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 87 e. Place the strands of wire overlapping each other inside of the brass splice band (Figure 9). f. Using crimp tool (Mopar P/N 05019912AA), crimp the brass splice band and wires together (Figure 10). g. Solder the connection together using rosin core type solder. DO NOT use acid core solder. CAUTION: All splices must be properly soldered. Failure to properly solder these wiring connectors can cause the ABS to become inoperative in the future. h. Center the shrink tubing over the splice joint. Using a heat gun, heat the surface of the shrink tubing until the shrink tubing is tightly sealed and sealant comes out of both ends of the shrink tubing (Figure 11). 5. After all of the terminals have been transferred or replaced, install the blue secondary terminal lock into the ABS control module wiring harness connector (Figure 8). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 88 6. Using a small mirror (Snap-on GA295 or equivalent), inspect the ABS control module connector pins for green corrosion and the connector housing for heat damage (Figure 12). > ABS control module connectors found with green corroded pins continue with Section D - ABS Control Module Replacement. > ABS control module connector housings found with heat damage continue with Section D - ABS Control Module Replacement. > ABS control module connectors found without heat damage or green corroded pins continue with Section E - Battery Tray Installation. D. ABS Control Module Replacement NOTE: Only ABS control modules with a heat damaged (melted) connector or green corroded connector pins, as determined by the inspection in Section B and C, require replacement. Very few vehicles are expected to require ABS control module replacement. 1. Disconnect the small ABS control module wiring connector from the ABS control module (Figure 13). 2. Remove the four mounting screws on the ABS control module (Figure 13). 3. Lift the module from the ABS hydraulic control unit and disconnect the solenoid connector located on the bottom side of the ABS control module. 4. Remove the ABS control module from the vehicle and discard. 5. Using a clean shop towel, clean the ABS control module mounting surface on the ABS hydraulic control unit. 6. Connect the solenoid connector to the new ABS control module and then place the module into position on the ABS hydraulic control unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 89 7. Install the four ABS control module mounting screws. Tighten the screws to 39 in. lbs (4.4 N.m). 8. Continue with Section E - Battery Tray Installation. E. Battery Tray Installation 1. If disconnected, spray the ABS control module connector and the ABS control module wiring harness connector with Electrolyte Detection and Neutralizing spray to ensure that all traces of acid have been neutralized. NOTE: When the spray remains an orange color, any remaining battery acid has been neutralized. 2. Using compressed air, carefully blow out the connector until completely dry. 3. If previously disconnected, connect the large and/or small wiring harness connectors to the ABS control module. 4. Transfer the battery temperature sensor from the old battery tray to the new battery tray (Figure 14). Then discard the old battery tray. 5. Place a small bead of RTV silicone rubber adhesive (P/N 04883971) onto the base of the new drain tube grommet. 6. Snap the new drain tube into position on the new battery tray (Figure 14). 7. While installing the new battery tray into position, route the drain tube through the original hole in the fender panel (Figure 15) and connect the battery temperature sensor electrical connector. 8. Install the battery tray mounting bolts. Tighten the bolts to 95 in. lbs. (10.7 N.m). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 90 9. Install the battery onto the new battery tray. 10. Install the "J" hook and battery hold down bracket. 11. Install the battery hold down retaining nuts. Tighten the nuts to 24 in. lbs. (2.7 N.m). 12. Connect the positive battery cable to the positive battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 13. Connect the negative battery cable to the negative battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 14. From inside the left wheel well housing, secure the battery tray drain tube to the frame rail bracket with the provided plastic tie strap (Figure 16). 15. If the ABS control module was replaced, connect the DRB III scan tool to the vehicle and program the rear axle ratio and tire size into the new control module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 91 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > NHTSA04V185000 > Apr > 04 > Recall 04V185000: ABS Control Module Corrosion Electronic Brake Control Module: All Technical Service Bulletins Recall 04V185000: ABS Control Module Corrosion DEFECT: On some van and wagon model vehicles equipped with 4-wheel antilock brake systems (ABS), aftermarket batteries may leak electrolyte onto the ABS control module connector, which can compromise the sealing integrity of the connector. This may allow development of a short circuit in the connector, which could eventually lead to a fire. REMEDY: Dealers will inspect the ABS control module connector for electrolyte damage and replace the connector as necessary. The manufacturer has not yet provided an owner notification for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > With RWAL Brakes Electronic Brake Control Module: Specifications With RWAL Brakes Mounting Screws ................................................................................................................................. ....................................................... 4 Nm (36 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > With RWAL Brakes > Page 98 Electronic Brake Control Module: Specifications With 4-Wheel Antilock Brakes Screws ................................................................................................................................................. ................................................. 4.4 Nm (39 inch lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > EBC 2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > EBC 2 > Page 101 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock Brake (CAB) Electronic Brake Control Module: Description and Operation Kelsey-Hayes EBC Controller Antilock Brake (CAB) The CAB is mounted under the hood, separately from the valve body, and has a microprocessor and circuits that: - monitor the brake switch input to tell whether or not to prepare for possible antilock braking - monitor the wheel speed sensor inputs to determine when a rear wheel is tending to lock up. - operate the integral control unit assembly during antilock braking based on comparing the speed sensor to information programmed in memory - detect ABS system related problems and take diagnostic action The CAB will disable antilock control and set a hard ignition latched trouble code if it detects one of the following conditions with itself: - (71) RAM Read/Write - (72) ROM Checksum - (73) Watchdog Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock Brake (CAB) > Page 104 Electronic Brake Control Module: Description and Operation Kelsey-Hayes EBC 325 Controller Antilock Brake (CAB) The CAB is mounted directly to the hydraulic control unit and includes a microprocessor and six solenoids that control brake pressure during antilock braking. The CAB also has circuits that monitor the following: - Brake switch input is monitored to determine whether or not to prepare for possible antilock braking. - Wheel speed sensors are monitored to determine when a wheel is tending to lock up. The CAB will operate the valves in the ECU to control braking pressure during antilock braking. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock Brake (CAB) > Page 105 Electronic Brake Control Module: Description and Operation With Four Wheel Antilock Brakes CAB/HCU The Controller Antilock Brake (CAB) is mounted on the top of the hydraulic control unit. The CAB operates the ABS system and is separate from other vehicle electrical circuits. CAB voltage source is through the ignition switch in the RUN position. The CAB contains dual microprocessors. A logic block in each microprocessor receives identical sensor signals. These signals are processed and compared simultaneously. The CAB contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the DRB scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock Brake (CAB) > Page 106 Electronic Brake Control Module: Description and Operation With Rear Wheel Antilock Brakes GENERAL INFORMATION RWAL Controller Antilock Brake (CAB) The Controller Antilock Brakes (CAB) is a microprocessor which handles testing, monitoring and controlling the ABS brake system operation. The CAB functions are: Perform self-test diagnostics. - Monitors the RWAL brake system for proper operation. - Controls the RWAL valve solenoids. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. SYSTEM SELF-TEST When the ignition switch is turned-on the microprocessor RAM and ROM are tested. If an error occurs during the test a Diagnostic Trouble Code (DTC) will be set into the RAM memory. However it is possible the DTC will not be stored in memory if the error has occurred in the RAM module were the DTC's are stored. Also it is possible a DTC may not be stored if the error has occurred in the ROM which signals the RAM to store the DTC. CAB INPUTS The CAB continuously monitors the speed of the differential ring gear by monitoring signals generated by the rear wheel speed sensor. The CAB determines a wheel locking tendency when it recognizes the ring gear decelerating too rapidly. The CAB monitors the following inputs to determine when a wheel locking tendency may exists: - Rear Wheel Speed Sensor - Brake Lamp Switch - Brake Warning Lamp Switch - Reset Switch - 4WD Switch (If equipped) CAB OUTPUTS The CAB controls the following outputs for antilock braking and brake warning information: RWAL Valve - ABS Warning Lamp - Brake Warning Lamp Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System Electronic Brake Control Module: Service and Repair Four Wheel Antilock Brake System NOTE: If the Controller Antilock Brake (CAB) needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. REMOVAL 1. Disconnect battery cables and remove the battery. 2. Remove the power distribution center. 3. Remove the battery and power distribution center mount. 4. Remove the washer reservoir mounting screws. 5. Lift up the reservoir and disconnect the pump motor connector and pump hose. 6. Remove the reservoir from the engine compartment. Harness Connector Locks 7. Push the harness connector locks to release the locks, then remove the connectors from the CAB. Pump Motor Connector 8. Disconnect the pump motor connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 109 Controller Mounting Screws 9. Remove screws attaching CAB to the Hydraulic Control Unit (HCU). 10. Remove the CAB. INSTALLATION 1. Place the CAB onto the HCU. NOTE: Insure the CAB seal is in position before installation. 2. Install the mounting screws and tighten to 4.4 Nm (39 inch lbs.). 3. Connect the pump motor harness. 4. Connect the harnesses to the CAB and lock the connectors. 5. Install the reservoir in the engine compartment. Connect the pump motor connector and pump hose. 6. Install the washer reservoir mounting screws. 7. Install the battery and power distribution center mount. 8. Install the power distribution center. 9. Install the battery and battery cables. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 110 Electronic Brake Control Module: Service and Repair Rear Wheel Antilock Brake System NOTE: If the Controller Antilock Brake (CAB) needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. REMOVAL 1. Remove the washer reservoir mounting screws. 2. Lift up the reservoir and disconnect the pump motor connector and pump hose. 3. Remove the reservoir from the engine compartment. 4. Disconnect battery cables and remove the battery. 5. Remove the power distribution center. 6. Remove the battery and power distribution center mount. 7. Remove the RWAL valve harness. 8. Pull up on the CAB harness connector lock release and remove the connector from the controller. 9. Remove controller mounting screws and remove controller. INSTALLATION 1. Position the controller on the mounting bracket and install the mounting screws. 2. Install the CAB harness connector into the controller and push down on the connector lock. 3. Install the RWAL valve harness connector into controller. 4. Install the battery and power distribution center mount. 5. Install the power distribution center. 6. Install the battery and battery cables. 7. Install the reservoir in the engine compartment. Connect the pump motor connector and pump hose. 8. Install the washer reservoir mounting screws. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Blower Motor Relay Blower Motor Relay: Description and Operation Blower Motor Relay SYSTEM OPERATION Front The front blower motor relay is a International Standards Organization (ISO)-type relay. The relay is a electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) directly to the blower motor. The relay is energized when the relay coil is provided a voltage signal by the ignition switch. This arrangement reduces the amount of battery current that must flow through the ignition switch. The blower motor relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motor receives no battery current. See Blower Motor Relay in the Diagnosis and Testing for more information. The front blower motor relay is located in the PDC in the engine compartment. Refer to the PDC label for blower motor relay identification and location. The blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Rear The blower motor relay for the optional rear heater-A/C unit is a International Standards Organization (ISO)-type relay. The relay is a electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) directly to the blower motor. The relay is energized when the relay coil is provided a voltage signal by the ignition switch. This arrangement reduces the amount of battery current that must flow through the ignition switch. The blower motor relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motor receives no battery current. See Blower Motor Relay in the Diagnosis and Testing for more information. The rear blower motor relay is located in a connector that is secured to the back of the rear heater-A/C unit housing in the passenger compartment. See Blower Motor Relay - Rear in the Removal and Installation for rear blower motor relay identification and location. The blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Blower Motor Relay > Page 117 Blower Motor Relay: Description and Operation High Speed Blower Motor Relay SYSTEM OPERATION Front The front blower motor electrical circuit uses a high speed blower motor relay. The high speed blower motor relay is a International Standards Organization (1S0)-type relay The relay is a electromechanical device that switches the blower motor to ground, bypassing the remainder of the blower motor feed circuit. The high speed blower motor relay is energized when the relay coil is provided a ground signal by the blower motor switch, and a battery feed from the ignition switch. When the relay is de-energized, the front blower motor ground feed is routed through the front blower motor switch and the blower motor resistor. See High Speed Blower Motor Relay in the Diagnosis and Testing for more information. The front high speed blower motor relay is located in the engine compartment, on a bracket that is secured under one of the screws for the top cover on the inboard side of the heater-A/C housing. The high speed blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Rear The optional rear heater-A/C unit blower motor electrical circuit uses a high speed blower motor relay The high speed blower motor relay is a International Standards Organization (IS0)-type relay The relay is a electromechanical device that switches the blower motor to ground, bypassing the remainder of the blower motor feed circuit. The high speed blower motor relay is energized when the relay coil is provided a ground signal by the blower motor switch, and a battery feed from the ignition switch. When the relay is de-energized, the rear blower motor ground feed is routed through the rear blower motor switch and the blower motor resistor. See High Speed Blower Motor Relay in the Diagnosis and Testing for more information. The rear high speed blower motor relay is located in a connector that is secured to the back of the rear heater-A/C unit housing in the passenger compartment. See High Speed Blower Motor Relay Rear in the Removal and Installation for rear high speed blower motor relay identification and location. The rear high speed blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay Blower Motor Relay: Testing and Inspection Blower Motor Relay Blower Motor Relay Relay Test The blower motor relays used for the front heater-only or heater-A/C systems and for the optional rear heater-A/C unit can be tested in the same manner. The front blower motor relay is located in the Power Distribution Center (PDC). The rear blower motor relay is located in a connector that is attached to the back of the rear heater-A/C unit. See Blower Motor Relay in the Removal and Installation for the procedures to remove the relay, to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to fused battery feed directly from a fuse in the Power Distribution Center (PDC), and should be hot at all times. Check for battery voltage at the PDC cavity for relay terminal 30. If OK, go to Step 3. If not OK repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 4. 3. The relay normally open terminal cavity (87) is connected to the blower motor. When the relay is energized, terminal 87 is connected to terminal 30 and provides full battery current to the blower motor feed circuit. There should be continuity between the PDC cavity for terminal 87 and the blower motor relay output circuit cavity of the blower motor wire harness connector at all times. If OK, go to Step 5. If not OK, repair the open circuit to the blower motor as required. 4. The coil battery terminal cavity (86) is connected to the ignition switch. When the ignition switch is placed in the On position, fused ignition switch output is directed from a fuse in the junction block to the relay electromagnetic coil to energize the relay. There should be battery voltage at the PDC cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 6. If not OK, repair the open circuit to the junction block fuse as required. 5. The coil ground terminal cavity (85) is connected to ground. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the PDC cavity for relay terminal 85 and a good ground at all times. If not OK, repair the open circuit as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 120 Blower Motor Relay: Testing and Inspection High Speed Blower Motor Relay Blower Motor Relay Relay Test The high speed blower motor relays used for the front heater-only or heater-A/C systems and for the optional rear heater-A/C unit can be tested in the same manner. The front high speed blower motor relay is located in the engine compartment on a bracket mounted to the inboard side of the heater-A/C housing. The rear high speed blower motor relay is located in a connector that is attached to the back of the rear heater-A/C unit. See Blower Motor Relay in the Removal and Installation procedures to remove the relay, to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the ground side of the front or rear blower motor. There should be continuity between the ground circuit cavity of the front or rear blower motor wire harness connector and the wire harness connector cavity for relay terminal 30 at all times. If OK, go to Step 3. If not OK, repair the open circuit to the front or rear blower motor as required. 2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 4. 3. The relay normally open terminal cavity (87) is connected to ground. When the relay is energized, terminal 87 is connected to terminal 30 and provides a direct path to ground for the front or rear blower motor. There should be continuity between the wire harness connector cavity for relay terminal 87 and ground at all times. If OK, go to Step 5. If not OK, repair the open circuit to ground as required. 4. The coil battery terminal cavity (86) is connected to the ignition switch. When the ignition switch is placed in the On position, fused ignition switch output is directed from a fuse in the junction block to the relay electromagnetic coil to energize the relay. There should be battery voltage at the wire harness connector cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 6. If not OK, repair the open circuit to the junction block fuse as required. 5. The coil ground terminal cavity (85) is connected to the high speed output circuit terminal of the front or rear blower motor switch. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the wire harness connector cavity for relay terminal 85 and the high speed output circuit terminal of the front or rear blower motor switch at all times. If not OK, repair the open circuit to the front or rear blower motor switch as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Page 121 Blower Motor Relay: Service and Repair Front 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for blower motor relay identification and location. 4. Unplug the blower motor relay from the PDC. 5. Install the blower motor relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Rear The rear blower motor relay is used only on models with the optional rear heater-A/C unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the rear heater-A/C unit. Rear Blower Motor Relay Remove/Install 3. Unplug the blower motor relay from the inboard relay wire harness connector, which is secured to the rear of the rear heater-A/C unit. 4. Install the blower motor relay by aligning the relay terminals with the cavities in the wire harness connector and pushing the relay firmly into place. 5. Reinstall the cover for the rear heater-A/C unit. 6. Connect the battery negative cable. 7. Test the relay operation. High Speed Blower Motor Relay Front 1. Disconnect and isolate the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Page 122 Front High Speed Blower Motor Relay Remove/Install 2. The high speed blower motor relay is retained by a snap fit to the blade of the mounting bracket on the inboard side of the heater-A/C housing. Unsnap the relay from the mounting bracket by sliding it downwards. 3. Unplug the wire harness connector from the high speed blower motor relay. 4. Install the high speed blower motor relay by aligning the relay terminals with the cavities in the relay wire harness connector and pushing the relay firmly into place. 5. Slide the molded receptacle on the high speed blower motor relay case back onto the blade of the mounting bracket until it snaps into place. 6. Connect the battery negative cable. 7. Test the relay operation. Rear The rear high speed blower motor resistor is used only on models with the optional rear heater-A/C unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the rear heater-A/C unit. Rear High Speed Blower Motor Relay Remove/Install 3. Unplug the high speed blower motor relay from the outboard relay wire harness connector, which is secured to the rear of the rear heater-A/C unit. 4. Install the high speed blower motor relay by aligning the relay terminals with the cavities in the wire harness connector and pushing the relay firmly into place. 5. Reinstall the cover for the rear heater-A/C unit. 6. Connect the battery negative cable. 7. Test the relay operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations Compressor Clutch Relay: Component Locations 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 127 A/C Compressor Clutch Relay Connector, PDC. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 128 A/C Compressor Clutch Relay Connector, PDC. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 129 Compressor Clutch Relay: Description and Operation SYSTEM OPERATION The compressor clutch relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The compressor clutch relay is a electromechanical device that switches battery current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay. The PCM responds to inputs from the heater-A/C mode control switch, the low pressure cut-off switch, the high pressure cut-off switch, and the fin sensing cycling clutch switch. See Compressor Clutch Relay in the Diagnosis and Testing for more information. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 130 Compressor Clutch Relay: Testing and Inspection Relay Test Compressor Clutch Relay The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 3. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 4. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 5. If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 6. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 131 Compressor Clutch Relay: Service and Repair Power Distribution Center REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug the compressor clutch relay from the PDC. 5. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 137 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 138 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 139 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 140 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 141 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 142 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 143 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 144 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 145 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 146 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 147 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 148 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 149 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 150 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 151 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 152 Audible Warning Device Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 153 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 154 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 155 Audible Warning Device Control Module: Electrical Diagrams 8w-45-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 156 8w-45-3 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 157 8w-45-4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 158 8w-45-5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 159 8w-45-6 NOTE: To view Diagrams referred to in these diagrams SEE Complete Body and Chassis Diagrams.. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 160 Audible Warning Device Control Module: Description and Operation SYSTEM OPERATION A Central Timer Module (CTM) is used on this vehicle when it is equipped with the optional Vehicle Theft Security System (VTSS). In addition to serving as the security system module, the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, and a Remote Keyless Entry (RKE) module in a single unit. The CTM is also able to control and integrate many of the additional electronic functions and features included on models with this option. The CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The horn relay is one of the outputs that the CTM can control. The CTM is programmed to energize or de-energize the horn relay in response to certain inputs from the Vehicle Theft Security System (VTSS) and the Remote Keyless Entry (RKE) system. Refer to Body and Frame/Locks/Power Locks Systems for more information on the RKE system. Refer to Accessories and Optional Equipment/Antitheft and Alarm Systems/Vehicle Theft/Security Systems for more information on the VTSS. The CTM is mounted under the instrument panel, to the inboard side of the left center instrument panel support. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Central Timer Module Replacement For diagnosis of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. The CTM controls features and functions of the power lock, illuminated entry, and Remote Keyless Entry (RKE) systems. The CTM receives hard wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio frequency inputs from the RKE transmitters. In response to those and many other inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the headlamp and horn relays, and the courtesy lamps. The RKE receiver within the CTM has a memory function to retain the vehicle access codes of at least one, but no more than four RKE transmitters. The receiver is designed to retain the transmitter codes in memory, even if the battery is disconnected. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the REE transmitter. - A delay lock feature. With the delay lock feature, if a side or rear door is still open when a lock request is received by the CTM, the module will automatically cycle all of the power lock motors to lock five seconds after the doors are closed. - An enhanced accident response feature will unlock all doors, then prevent the power door lock system from locking the doors for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors and the liftgate after the vehicle reaches a speed of about 24 kilometers-per- hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. The CTM is mounted under the instrument panel, to the inboard side of the left center instrument panel support. Refer to Central Timer Module Replacement. The programmable features of the CTM can be enabled or disabled using the DRB scan tool as described in the proper Diagnostic Procedures. For diagnosis of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. A Central Timer Module (CTM) is used on this vehicle when it is equipped with the optional Vehicle Theft Security System (VTSS). In addition to serving as the security system module, the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, and a Remote Keyless Entry (RKE) module in a single unit. The CTM is also able to control and integrate many of the additional electronic functions and features included on models with this option. The CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 161 hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. One of the features that the CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard--wired inputs from the door ajar, front door lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp (or security) relay, horn relay; and the security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS. The CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering function; of the VTSS. The CTM is mounted under the instrument panel, to the inboard side of the left center instrument panel support. Refer to Instrument Panel, Gauges and Warning Indicators/Audible Warning Device Control Module/ Central Timer Module Replacement. The programmable features of the CTM can be enabled or disabled using the DRB scan tool as described in the proper Diagnostic Procedures. For diagnosis of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 162 Audible Warning Device Control Module: Testing and Inspection NOTE: The following tests may not prove conclusive in the diagnosis of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the CTM requires the use of a DRB scan tool. The CTM is used on models that are equipped with the optional Vehicle Theft Security System (VTSS). If the problem being diagnosed involves only the RKE horn chirp feature, see Horn Relay in the Diagnosis and Testing. If the relay checks OK; or if the problem being diagnosed involves the rolling door locks, door lock inhibit, or enhanced accident response features, further diagnosis of the CTM should be performed using a DRB scan tool. 1. Check the fused B(+) fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Check the fused ignition switch output fuse in the junction block. If OK, go to Step 5. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 4. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output fuse in the junction block. If OK, turn the ignition switch to the Off position and go to Step 6. If not OK, repair the open circuit to the ignition switch as required. 5. Disconnect and isolate the battery negative cable. Access and unplug the CTM wire harness connectors. Refer to Instrument Panel, Gauges and Warning Indicators/Audible Warning Device Control Module/Central Timer Module Replacement. 6. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 8. If not OK, repair the connections as required. 7. Probe the ground circuit cavity in the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity If OK, go to Step 9. If not OK, repair the open circuit(s) to ground as required. 8. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity in the 14-way CTM wire harness connector. If OK, go to Step 10. If not OK, repair the open circuit to the fuse in the junction block as required. 9. Probe the door lock switch output (lock) circuit cavity in the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 11. If not OK, repair the open circuit from either or both power lock switch(s) to the CTM as required. 10. Probe the door lock switch output (unlock) circuit cavity in the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 12. If not OK, repair the open circuit from either or both power lock switch(s) to the CTM as required. 11. Disconnect and isolate the battery negative cable. Reinstall the wire harness connectors to the CTM. Connect the battery negative cable. Back probe the door lock driver circuit cavity in the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 13. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 12. Still back probing the door lock driver circuit cavity in the 18-way CTM wire harness connector, open the side or rear cargo door. Move the power lock switch to the Lock position or press the Lock button of the RKE transmitter. Now close all of the doors. Within five seconds of the last door closing, there should be battery voltage on the door lock driver circuit. If OK, go to Step 14. If not OK, replace the faulty CTM. 13. Back probe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter If OK. see Power Lock Motor in the Diagnosis and Testing. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 163 Audible Warning Device Control Module: Service and Repair A Central Timer Module (CTM) is only used on high-line versions of this vehicle that are also equipped with the Vehicle Theft Security System (VTSS). See Central Timer Module in the General information. Before replacing a CTM, use a DRB scan tool to determine the current settings for tile CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the engine cover from the passenger compartment. Central Timer Module Remove/Install 3. Remove the three screws that secure the CTM to the inboard side of the left center instrument panel support. 4. Pull the CTM away from its mounting location far enough to access and unplug the two wire harness connectors. 5. Remove the CTM from the instrument panel. 6. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). NOTE: If a new Central Timer Module is installed, the programmable features must be enabled and or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Service and Repair Daytime Running Lamp Control Unit: Service and Repair Daytime Running Light Module The headlamps on vehicles sold in Canada will illuminate when the vehicle is started. The lamps illuminate at less than 50% of normal intensity. To disable the DRLM, set park bake. REMOVAL The Daytime Running Light Module (DRLM) is mounted in the engine compartment on the bottom of the cowl plenum next to the windshield wiper motor. 1. Remove the bolts holding the (DRLM) and bracket to the vehicle. 2. Disconnect the electrical connector. INSTALLATION 1. Connect the electrical connector. 2. Install the bolts holding the (DRLM) and bracket to the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams VTSS Headlamp Relay Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Page 171 Headlamp Relay: Description and Operation SYSTEM OPERATION The headlamp (or security) relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The headlamp relay is a electromechanical device that switches battery current to the headlamps when the high-line Central Timer Module (CTM) grounds the relay coil. See Headlamp Relay in the Diagnosis and Testing for more information. The headlamp relay is located in a connector that is taped back to the headlamp switch takeout of the instrument panel wire harness in the passenger compartment. To service the headlamp relay remove the headlamp switch mounting screws and pull the switch and wire harness out from the instrument panel far enough to access the relay and connector. The headlamp relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Page 172 Headlamp Relay: Service and Repair REMOVAL AND INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Headlamp Relay Remove/Install 1. Disconnect and isolate the battery negative cable. 2. Remove the headlamp switch from the instrument panel, but do not unplug the wire harness connectors. Refer to Lighting and Horns/Headlamp Switch Replacement. 3. Pull the headlamp switch out from the instrument panel far enough to access the headlamp relay, which is taped to the headlamp switch takeout of the instrument panel wire harness. 4. Remove the tape that secures the headlamp relay and its connector to the wire harness. 5. Unplug the headlamp relay from its wire harness connector. 6. Install the headlamp relay by aligning the relay terminals with the cavities in the wire harness connector and pushing the relay firmly into place. 7. Tape the headlamp relay and its connector back to the wire harness. 8. Reinstall the headlamp switch in the instrument panel. Refer to Lighting and Horns/Headlamp Switch Replacement. 9. Connect the battery negative cable. 10. Test the relay operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Description and Operation Horn Relay: Description and Operation SYSTEM OPERATION The horn relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The horn relay is a electromechanical device that switches battery current to the horn when the horn switch grounds the relay coil. See Horn Relay in the Diagnosis and Testing for more information. The horn relay is located in the junction block, which is located on the driver side end of the instrument panel in the passenger compaftment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the junction block until further diagnosis is completed. The horn relay cannot be repaired and, if faulty or damaged, it must be replaced. The horn relay is a component of the Remote Key-less Entry (RKE) system only on vehicles equipped with the optional Vehicle Theft Security System (VTSS). The horn relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The horn relay is a electromechanical device that switches battery current to the horn when the horn switch or the Central Timer Module (CTM) grounds the relay coil. See Horn Relay in the Diagnosis and Testing for more information. The horn relay is located in the junction block, which is located on the driver side end of the instrument panel in the passenger compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the junction block until further diagnosis is completed. The horn relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Description and Operation > Page 176 Horn Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Test Horn Relay The horn relay is located in the junction block in the passenger compartment. Remove the horn relay from the junction block to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. if OK, go to Step 3. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 electromagnet. should be 75 - 5 Ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity 30. is connected to battery voltage and should be hot at all times. If OK, go to Step 3. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal 87A. is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 4. 3. The relay normally open terminal 87. is connected to the common feed terminal 30. in the energized position. This terminal supplies battery voltage to the horns. There should be continuity between the cavity for relay terminal 87 and the horn relay output circuit cavity of each horn wire harness connector at all times. If OK, go to Step 5. If not OK, repair the open circuit to the horns. as required. 4. The coil battery terminal 86. is connected to the electromagnet in the relay. It is connected to battery voltage and should be hot at all times. Check for battery voltage at the cavity for relay terminal 86. If OK, go to Step 6. If not OK, repair the open circuit to the fuse in the PDC as required. 5. The coil ground terminal 85. is connected to the electromagnet in the relay It is grounded through the horn switch when the horn switch is depressed. On vehicles equipped with the Vehicle Theft Security System VTSS., the horn relay coil ground terminal can also be grounded by the Central Timer Module CTM. in response to certain inputs related to the VTSS or Remote Keyless Entry (RKE). system. Check for continuity to ground at the cavity for relay terminal 85. There should be continuity with the horn switch depressed, and no continuity with the horn switch released. If not OK, see Horn Switch in the Diagnosis and Testing. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The horn relay is located in the junction block in the passenger compartment. Remove the horn relay from the junction block to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay circuits. If not OK, replace the faulty relay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Description and Operation > Page 177 Horn Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the end cap from the driver side end of the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel End Cap Replacement. Junction Block 3. Unplug the horn relay from the junction block. 4. Install the horn relay by aligning the relay terminals with the cavities in the junction block and pushing the relay firmly into place. 5. Connect the battery negative cable. 6. Test the relay operation. 7. Reinstall the end cap on the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel End Cap Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Power Distribution Center, Battery, Windshield Washer Reservoir Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Module Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 188 Central Timer Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 191 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 192 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 193 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 194 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 195 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 196 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 197 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 198 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 199 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 200 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 201 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 202 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 203 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 204 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 205 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 206 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 207 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 208 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 209 Body Control Module: Connector Views CTM Connector CTM Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 210 Body Control Module: Electrical Diagrams Central Timer Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 211 Vehicle Communications Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Central Timer Module Description Body Control Module: Description and Operation Central Timer Module Description The AB HIGH LINE utilize a Central Timer Module (CTM). The Base AB RAM VAN will not be addressed in this manual. For concerns about the Base AB VAN, please refer to the appropriate service and repair article. The CTM performs most of the typical functions a Body Control Module would perform. The CTM provides the following features: - Remote Keyless Entry (RKE) - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks WIRKE - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Vehicle Theft Security System (VTSS) The module is located on the left center instrument panel support. It contains a white 18-way and a green 14-way connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Central Timer Module Description > Page 214 Body Control Module: Description and Operation System Description and Functional Operation The body system on the 1998 AB HIGH LINE consists of three modules that communicate over the CCD bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-Lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication. The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are performed through the Serial Communication Interface of SCI, the same as previous years. All of the information about the functioning of all the system is organized, controlled, and communicated by the CCD bus, which is described in Section 3 (CCD Bus) of this general information section. Through the CCD bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all the information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics Identification of Systems The vehicle Systems that are part of the "body" system are: - Airbag System (ACM) - Central Timer Module (CTM) - Instrument Cluster (MIC) - Vehicle Communication Diagnostic Strategies Diagnosis of the central timer module (CTM) is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem verification of proper operation Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM Technical Service Bulletin # 831 Date: 990601 Recall - Reprogram PCM June 1999 California Emissions Recall No. 831 Reprogram Powertrain Control Module Models 1998 (DN) Dodge Durango (with a 5.9L engine and automatic transmission) (AB) Dodge Ram Van/Wagon (with a 5.9L engine and automatic transmission) (ZJ) Jeep(R) Grand Cherokee (with a 5. 9L engine and automatic transmission) (AN) Dodge Dakota (with 5.2L engine and manual transmission or 5.9L engine and automatic transmission) (BR/BE)Dodge Ram Pickup (with a 5.2L engine and manual transmission, 5.9L engine and automatic transmission or 8.0L engine) NOTE: This recall applies only to certain vehicles equipped with a California emission control system (sales code NAE) built through April 30, 1998 (MDH 0430XX). Subject The On-Board Diagnostic (OBD) system on about 18,000 of the above vehicles may not detect evaporative emissions purge system malfunctions as required by California Emission Regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update labels and Authorized Modifications labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance PCM Update Previously Performed 08831181 0.2 hours Reprogram Powertrain Control Module 08831182 0.5 hours Add the cost of the labels plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 225 Not Applicable Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD831". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure The DRB III(R) with either MDS1 or MDS2 is required to perform this repair. ^ If using the MDS1 and DRB III, the MDS must be operating at release 21 or higher and TIL CD release 1184 or higher must be installed. ^ If using the MDS2 and DRB III, the system must be operating at CIS CD2034 or higher. Using the MDS1 1. Connect the MDS1 (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 - CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU screen. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III UPDATE on the DRB III MAIN MENU. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER REPROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS1 AND DRB III on the MDS1, then press NEXT MENU. 7. FOLLOW THE STEPS PRESENTED ON THE MDS1 and DRB III that will allow the DRB III to obtain the current part number of the PCM. 8. The MDS1 will display the part number of the PCM on the vehicle and the appropriate replacement part number(s). Press NEXT MENU to begin programming. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 226 9. The MDS and DRB III will prompt the operator for any action needed during the remainder of the programming process. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Step C. Using the MDS2 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. B. Install Authorized Software Update Label Fig. 1 Type or print (with a ballpoint pen) the necessary information on the "Authorized Software Update" label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Label Fig. 2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 227 Type or print (with a ballpoint pen) the necessary information shown in Figure 2 onto the Authorized Modifications Label. Then attach the label near the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Owner Letter EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE Dear DaimlerChrysler Vehicle Owner: DaimlerChrysler has determined that some 1998 Dodge Dakota, Durango, Ram Van/Wagon, Ram Truck, and Jeep(R) Grand Cherokee vehicles, equipped with a V-8 or V-10 engine, may be in violation of California Emissions Regulations. The problem is... The On-Board Diagnostic (OBD) system on your vehicle (identified on the enclosed form) may not detect evaporative emissions purge system malfunctions as required by California Emissions Regulations. As a result, the OBD system on your vehicle may not illuminate the "Check Engine" light if the evaporative emissions purge system malfunctions. This could cause your vehicle to emit hydrocarbon levels above the limits that were established to protect the public health from the dangers of air pollution. Hydrocarbons (unburned fuel) combined with oxides of nitrogen, in the presence of sunlight, can cause the formation of ozone. These pollutants are the primary components of smog. What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will reprogram your vehicle's powertrain control module. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer right away to schedule a service appointment. ^ Bring the enclosed Owner Notification form with you to your dealer. It identifies the required service to the dealer. If you live in California and don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. How the state knows that the recall has been performed... State of California regulations require DaimlerChrysler to provide the Department of Motor Vehicles with a record of all vehicles that have not had the recall service performed. If you live in the state of California and your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. In order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. We are sorry for any inconvenience but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you for your attention to this important matter. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates Powertrain Control Module: All Technical Service Bulletins Engine Controls/Charging System Manual Updates NUMBER: 26-08-99F GROUP: Miscellaneous DATE: August, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998-2.5L, 3.9L, 5.2L, 5.9L, 8.0 SFI/Mechanically Injected Diesel Diagnostic Manual Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the Charging System Low Test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 233 71 Revision to the 5.2/5.9L PCM Wiring Schematic Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 234 744 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 > Recall Reprogram PCM Technical Service Bulletin # 831 Date: 990601 Recall - Reprogram PCM June 1999 California Emissions Recall No. 831 Reprogram Powertrain Control Module Models 1998 (DN) Dodge Durango (with a 5.9L engine and automatic transmission) (AB) Dodge Ram Van/Wagon (with a 5.9L engine and automatic transmission) (ZJ) Jeep(R) Grand Cherokee (with a 5. 9L engine and automatic transmission) (AN) Dodge Dakota (with 5.2L engine and manual transmission or 5.9L engine and automatic transmission) (BR/BE)Dodge Ram Pickup (with a 5.2L engine and manual transmission, 5.9L engine and automatic transmission or 8.0L engine) NOTE: This recall applies only to certain vehicles equipped with a California emission control system (sales code NAE) built through April 30, 1998 (MDH 0430XX). Subject The On-Board Diagnostic (OBD) system on about 18,000 of the above vehicles may not detect evaporative emissions purge system malfunctions as required by California Emission Regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update labels and Authorized Modifications labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance PCM Update Previously Performed 08831181 0.2 hours Reprogram Powertrain Control Module 08831182 0.5 hours Add the cost of the labels plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 > Recall Reprogram PCM > Page 239 Not Applicable Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD831". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure The DRB III(R) with either MDS1 or MDS2 is required to perform this repair. ^ If using the MDS1 and DRB III, the MDS must be operating at release 21 or higher and TIL CD release 1184 or higher must be installed. ^ If using the MDS2 and DRB III, the system must be operating at CIS CD2034 or higher. Using the MDS1 1. Connect the MDS1 (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 - CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU screen. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III UPDATE on the DRB III MAIN MENU. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER REPROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS1 AND DRB III on the MDS1, then press NEXT MENU. 7. FOLLOW THE STEPS PRESENTED ON THE MDS1 and DRB III that will allow the DRB III to obtain the current part number of the PCM. 8. The MDS1 will display the part number of the PCM on the vehicle and the appropriate replacement part number(s). Press NEXT MENU to begin programming. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 > Recall Reprogram PCM > Page 240 9. The MDS and DRB III will prompt the operator for any action needed during the remainder of the programming process. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Step C. Using the MDS2 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. B. Install Authorized Software Update Label Fig. 1 Type or print (with a ballpoint pen) the necessary information on the "Authorized Software Update" label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Label Fig. 2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 > Recall Reprogram PCM > Page 241 Type or print (with a ballpoint pen) the necessary information shown in Figure 2 onto the Authorized Modifications Label. Then attach the label near the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Owner Letter EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE Dear DaimlerChrysler Vehicle Owner: DaimlerChrysler has determined that some 1998 Dodge Dakota, Durango, Ram Van/Wagon, Ram Truck, and Jeep(R) Grand Cherokee vehicles, equipped with a V-8 or V-10 engine, may be in violation of California Emissions Regulations. The problem is... The On-Board Diagnostic (OBD) system on your vehicle (identified on the enclosed form) may not detect evaporative emissions purge system malfunctions as required by California Emissions Regulations. As a result, the OBD system on your vehicle may not illuminate the "Check Engine" light if the evaporative emissions purge system malfunctions. This could cause your vehicle to emit hydrocarbon levels above the limits that were established to protect the public health from the dangers of air pollution. Hydrocarbons (unburned fuel) combined with oxides of nitrogen, in the presence of sunlight, can cause the formation of ozone. These pollutants are the primary components of smog. What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will reprogram your vehicle's powertrain control module. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer right away to schedule a service appointment. ^ Bring the enclosed Owner Notification form with you to your dealer. It identifies the required service to the dealer. If you live in California and don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. How the state knows that the recall has been performed... State of California regulations require DaimlerChrysler to provide the Department of Motor Vehicles with a record of all vehicles that have not had the recall service performed. If you live in the state of California and your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. In order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. We are sorry for any inconvenience but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you for your attention to this important matter. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution Powertrain Control Module: All Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions Powertrain Control Module: All Technical Service Bulletins Engine Controls/Fuel System - Service Manual Revisions NUMBER: 26-12-97H GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L, 3.9L, 5.2L, 8.0L Powertrain Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the "No Cam Signal at PCM" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 250 29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 251 56 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 252 58 Revision to the "Fuel Level Sending Unit" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 253 412 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates Powertrain Control Module: All Technical Service Bulletins Engine Controls/Charging System Manual Updates NUMBER: 26-08-99F GROUP: Miscellaneous DATE: August, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998-2.5L, 3.9L, 5.2L, 5.9L, 8.0 SFI/Mechanically Injected Diesel Diagnostic Manual Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the Charging System Low Test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 259 71 Revision to the 5.2/5.9L PCM Wiring Schematic Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 260 744 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution Powertrain Control Module: All Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions Powertrain Control Module: All Technical Service Bulletins Engine Controls/Fuel System - Service Manual Revisions NUMBER: 26-12-97H GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L, 3.9L, 5.2L, 8.0L Powertrain Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the "No Cam Signal at PCM" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 269 29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 270 56 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 271 58 Revision to the "Fuel Level Sending Unit" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 272 412 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 273 Powertrain Control Module: Specifications Mounting Screws 1 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 274 Powertrain Control Module: Locations Fig 1 Powertrain Control Module The Powertrain Control Module (PCM) is located under the hood; mounted to the cowling, near the wiper motor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 277 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 278 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 279 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 280 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 281 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 282 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 283 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 284 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 285 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 286 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 287 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 288 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 289 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 290 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 291 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 292 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 293 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 294 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 295 Powertrain Control Module: Connector Views Powertrain Control Module Connectors Powertrain Control Module C1 - Black Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 296 C1 - Black C2 - White C2 - White C3 - Grey Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 297 C3 - Grey Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 298 Powertrain Control Module: Description and Operation SYSTEM OPERATION Powertrain Control Module (PCM) The Powertrain Control Module (PCM) is located in the engine compartment. The ignition system is controlled by the PCM. NOTE: Base ignition timing by rotation of distributor is not adjustable. The PCM opens and closes the ignition coil ground circuit to operate the ignition coil. This is done to adjust ignition timing, both initial (base) and advance, and for changing engine operating conditions. The amount of electronic spark advance provided by the PCM is determined by five input factors: engine coolant temperature, engine rpm, intake manifold temperature, manifold absolute pressure and throttle position. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Module Replacement Powertrain Control Module: Service and Repair Module Replacement Fig 1 Powertrain Control Module REMOVAL 1. Disconnect the negative battery cable at battery. 2. Carefully unplug the three 32-way connectors from PCM. 3. Remove three Powertrain Control Module (PCM) mounting bolts and remove PCM from vehicle. INSTALLATION 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 4 N.m (35 in. lbs.). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary 4. Install three 32-way connectors. 5. Install battery cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Module Replacement > Page 301 Powertrain Control Module: Service and Repair A Note About PCM Replacement Important Note: If the Powertrain Control Module has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS, Airbag and SKIM modules. In addition, if the vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. For ABS and Airbag Systems: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Airbag modules. For SKIM Theft Alarm: 1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. 3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM (this is required to allow the vehicle to start with the new PCM). 4. If three attempts are made to enter secured access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lock out mode, leave the ignition key in the Run/Start position for one hour. Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Auto Shutdown Relay Connector, Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 305 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 306 Auto Shutdown Relay Connector, Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 307 Automatic Shut Down (ASD) Relay: Description and Operation SYSTEM OPERATION As one of its functions, the (ASD) relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 308 Automatic Shut Down (ASD) Relay: Testing and Inspection Fig. 24 Asd And Fuel Pump Relay Terminals The relay terminal numbers can be found on the bottom of the relay: - Terminal number 30 is connected to battery voltage and can be switched or B+ (hot) at all times. - The center terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the component being operated. - Terminal number 86 is connected to a switched (+) power source. - Terminal number 85 is grounded by the Powertrain Control Module (PCM). TESTING 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. - Resistance value (ohms) should be 75 +/- 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. - Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. - Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). - Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. - Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. - Continuity should now be present between terminals number 87 and 30. - Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 volt power source. If continuity or resistance tests did not pass, replace relay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 309 Automatic Shut Down (ASD) Relay: Service and Repair Fig 2 Power Distribution Center The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC coven 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. - Also check the heights of relay terminal pins at PDC. - Pin height should be same for all pins. - Repair as necessary before installing relay. 2. Push the relay into the connector. 3. Install the relay cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Fuel Pump Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 314 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 315 Fuel Pump Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 316 Fuel Pump Relay: Service and Repair Fig 2 Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 317 Power Distribution Center -- Under The Hood, Near The Brake Master Cylinder The fuel pump and automatic shutdown (ASD) relays are located in the Power Distribution Center (PDC). The PDC is located in the engine compartment in front of the brake master cylinder. Refer to label on PDC cover for relay location. Check the terminals in the PDC relay connector for corrosion or damage before installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Auto Shutdown Relay Connector, Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 321 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 322 Auto Shutdown Relay Connector, Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 323 Automatic Shut Down (ASD) Relay: Description and Operation SYSTEM OPERATION As one of its functions, the (ASD) relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 324 Automatic Shut Down (ASD) Relay: Testing and Inspection Fig. 24 Asd And Fuel Pump Relay Terminals The relay terminal numbers can be found on the bottom of the relay: - Terminal number 30 is connected to battery voltage and can be switched or B+ (hot) at all times. - The center terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the component being operated. - Terminal number 86 is connected to a switched (+) power source. - Terminal number 85 is grounded by the Powertrain Control Module (PCM). TESTING 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. - Resistance value (ohms) should be 75 +/- 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. - Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. - Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). - Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. - Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. - Continuity should now be present between terminals number 87 and 30. - Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 volt power source. If continuity or resistance tests did not pass, replace relay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 325 Automatic Shut Down (ASD) Relay: Service and Repair Fig 2 Power Distribution Center The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC coven 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. - Also check the heights of relay terminal pins at PDC. - Pin height should be same for all pins. - Repair as necessary before installing relay. 2. Push the relay into the connector. 3. Install the relay cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 816 > Feb > 99 > Recall Airbag Electronic Control Module Technical Service Bulletin # 816 Date: 990201 Recall - Airbag Electronic Control Module February 1999 Safety Recall No. 816 Airbag Electronic Control Module Models 1998 (AB) Dodge Ram Vans and Wagons NOTE: This recall applies only to vehicles built through June 5, 1998 (MDH 060517). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using the DIAL VIP System. Subject If an object impacts the airbag electronic control module (AECM) on about 46,000 of the above vehicles, the module may inadvertently deploy both airbags. Inadvertent airbag deployment can injure a front seat occupant. Repair The AECM must be replaced and a protective cover must be installed over the new AECM. Part Number Description CCF18160 AECM Package Each package contains the following components: Quantity Description 1 AECM 1 AECM Cover 3 Screws - AECM-to-Floor Pan Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough AECM Packages to service about 25% of those vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced, must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace AECM and install cover 08816182 0.4 hours Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing instructions Parts Return Not required. Dealer Notification & Vehicle List Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 816 > Feb > 99 > Recall Airbag Electronic Control Module > Page 335 All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the CMMS and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD816". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed, Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive Last Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Using a trim panel removal tool, remove the push-in fasteners that attach the seat riser trim shield to the rear of the driver's seat riser (if equipped) (Figure 1). Set the trim shield aside. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 816 > Feb > 99 > Recall Airbag Electronic Control Module > Page 336 3. Remove the power seat wiring harness connector from the front riser crossmember and then disconnect the connector (if equipped) (Figure 2). 4. Remove the nuts that attach the driver's seat riser to the floor pan (Figure 2). 5. Remove the driver's seat assembly from the vehicle. 6. Disconnect the airbag electronic control module (AECM) wiring connector. 7. Remove the three (3) screws that attach the AECM to the floor pan mounting bracket (Figure 3). Discard the screws. 8. Remove the AECM. Destroy the old AECM connector pins and then discard the old AECM. 9. Install the supplied AECM. Position the AECM on the floor pan mounting bracket with the arrow on the housing pointing forward (Figure 3). 10. Install the three provided AECM mounting screws. Tighten the screws to 105 in-lbs (11.8 N.m). 11. Connect the AECM wiring connector. Make sure that the connector latches are fully engaged. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 816 > Feb > 99 > Recall Airbag Electronic Control Module > Page 337 12. Clean the floor pan area around the AECM. 13. Remove the "peel and stick" backing paper from the adhesive strips on the provided AECM cover. 14. Install the cover over the AECM. Press down firmly to ensure that the adhesive strips are securely attached to the floor pan (Figure 4). Note: Position the cover so that the vehicle wiring harnesses are routed through the cover openings. Ensure that the power seat wiring harness is not trapped under the cover. 15. Install the driver's seat assembly into the vehicle. 16. Install the nuts that attach the driver's seat riser to the floor (Figure 2). Tighten the nuts to 55 ft-lbs (75 N.m). 17. Connect the power driver seat wiring harness connector and attach it to the front riser crossmember (if equipped) (Figure 2). 18. Attach the riser trim shield to the rear of the driver's seat riser with the push-in fasteners (if equipped) (Figure 1). 19. Turn the ignition switch to the "RUN" position. 20. Connect the negative battery cable. 21. From outside the vehicle, turn the ignition switch to the "OFF" position for about 10 seconds and then turn it back to the "RUN" position. 22. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light, or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG ELECTRONIC CONTROL MODULE Dear Ram Van or Wagon Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. DaimlerChrysler Corporation has determined that a defect, which relates to motor vehicle safety, exists in some 1998 Dodge Ram Vans and Wagons. The problem is... If an object impacts the airbag electronic control module (AECM) under the driver's seat of your Ram van or wagon (identified on the enclosed form), the module may inadvertently deploy both airbags. Inadvertent airbag deployment can injure a front seat occupant. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 816 > Feb > 99 > Recall Airbag Electronic Control Module > Page 338 What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the AECM and install a protective cover over it. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, DC 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. Washington, DC area residents may call 1-202-366-0123. We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. 816 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module Technical Service Bulletin # 816 Date: 990201 Recall - Airbag Electronic Control Module February 1999 Safety Recall No. 816 Airbag Electronic Control Module Models 1998 (AB) Dodge Ram Vans and Wagons NOTE: This recall applies only to vehicles built through June 5, 1998 (MDH 060517). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using the DIAL VIP System. Subject If an object impacts the airbag electronic control module (AECM) on about 46,000 of the above vehicles, the module may inadvertently deploy both airbags. Inadvertent airbag deployment can injure a front seat occupant. Repair The AECM must be replaced and a protective cover must be installed over the new AECM. Part Number Description CCF18160 AECM Package Each package contains the following components: Quantity Description 1 AECM 1 AECM Cover 3 Screws - AECM-to-Floor Pan Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough AECM Packages to service about 25% of those vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced, must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace AECM and install cover 08816182 0.4 hours Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing instructions Parts Return Not required. Dealer Notification & Vehicle List Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module > Page 344 All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the CMMS and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD816". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed, Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive Last Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Using a trim panel removal tool, remove the push-in fasteners that attach the seat riser trim shield to the rear of the driver's seat riser (if equipped) (Figure 1). Set the trim shield aside. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module > Page 345 3. Remove the power seat wiring harness connector from the front riser crossmember and then disconnect the connector (if equipped) (Figure 2). 4. Remove the nuts that attach the driver's seat riser to the floor pan (Figure 2). 5. Remove the driver's seat assembly from the vehicle. 6. Disconnect the airbag electronic control module (AECM) wiring connector. 7. Remove the three (3) screws that attach the AECM to the floor pan mounting bracket (Figure 3). Discard the screws. 8. Remove the AECM. Destroy the old AECM connector pins and then discard the old AECM. 9. Install the supplied AECM. Position the AECM on the floor pan mounting bracket with the arrow on the housing pointing forward (Figure 3). 10. Install the three provided AECM mounting screws. Tighten the screws to 105 in-lbs (11.8 N.m). 11. Connect the AECM wiring connector. Make sure that the connector latches are fully engaged. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module > Page 346 12. Clean the floor pan area around the AECM. 13. Remove the "peel and stick" backing paper from the adhesive strips on the provided AECM cover. 14. Install the cover over the AECM. Press down firmly to ensure that the adhesive strips are securely attached to the floor pan (Figure 4). Note: Position the cover so that the vehicle wiring harnesses are routed through the cover openings. Ensure that the power seat wiring harness is not trapped under the cover. 15. Install the driver's seat assembly into the vehicle. 16. Install the nuts that attach the driver's seat riser to the floor (Figure 2). Tighten the nuts to 55 ft-lbs (75 N.m). 17. Connect the power driver seat wiring harness connector and attach it to the front riser crossmember (if equipped) (Figure 2). 18. Attach the riser trim shield to the rear of the driver's seat riser with the push-in fasteners (if equipped) (Figure 1). 19. Turn the ignition switch to the "RUN" position. 20. Connect the negative battery cable. 21. From outside the vehicle, turn the ignition switch to the "OFF" position for about 10 seconds and then turn it back to the "RUN" position. 22. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light, or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG ELECTRONIC CONTROL MODULE Dear Ram Van or Wagon Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. DaimlerChrysler Corporation has determined that a defect, which relates to motor vehicle safety, exists in some 1998 Dodge Ram Vans and Wagons. The problem is... If an object impacts the airbag electronic control module (AECM) under the driver's seat of your Ram van or wagon (identified on the enclosed form), the module may inadvertently deploy both airbags. Inadvertent airbag deployment can injure a front seat occupant. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module > Page 347 What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the AECM and install a protective cover over it. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, DC 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. Washington, DC area residents may call 1-202-366-0123. We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. 816 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 348 Air Bag Control Module: Locations Module Locations Air Bag Control Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 349 Air Bag Control Module: Diagrams ACM Connector ACM Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 350 Air Bag Control Module: Description and Operation SYSTEM OPERATION The Airbag Control Module (ACM) is secured to a bracket on the floor panel underneath the driver side front seat in the passenger compartment of the vehicle. The ACM contains a microprocessor that contains the airbag system logic, the impact sensor, and an energy storage capacitor. The ACM system logic includes On-Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry on the Chrysler Collision Detection (CCD) data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the CCD data bus to turn on the airbag indicator lamp. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate signaled by the impact sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the air-bag system components. Only one impact sensor is used in this airbag system. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 351 Air Bag Control Module: Service and Repair REMOVAL AND INSTALLATION WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - NEVER STRIKE OR KICK THE AIR BAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. ALWAYS REINSTALL THE AIRBAG CONTROL MODULE PROTECTIVE COVER. 1. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Reach under the driver side front seat to access and unplug the wire harness connector from the Air-Bag Control Module (ACM). Airbag Control Module Remove/Install 3. Remove the three screws that secure the ACM to the mounting bracket on the floor panel under the driver seat. 4. Remove the ACM from the floor panel mounting bracket. 5. When installing the ACM, position the unit with the arrow on the ACM housing pointing forward. 6. Secure the ACM to the floor panel mounting bracket with the three mounting screws. Tighten the mounting screws to 11.8 N.m (105 in. lbs.). 7. Plug in the wire harness connector to the ACM. Be certain that the connector latches are fully engaged. 8. Do not connect the battery negative cable at this time. See Airbag System in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 356 Starter Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 357 Starter Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 358 Starter Relay: Description and Operation SYSTEM OPERATION The starter relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay However, the micro-relay terminal orientation (or footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The starter relay is a electromechanical device that switches battery current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. See Starter Relay/Testing and Inspection/Procedures. The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. The starter relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 359 Starter Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for starter relay identification and location. 4. Unplug the starter relay from the PDC. 5. Install the starter relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 370 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 371 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 377 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 378 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 379 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 383 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 384 Transmission Control Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation Wiper Control Module: Description and Operation SYSTEM OPERATION Intermittent Wipe Module An intermittent wipe module is used on vehicles that are not equipped with the optional Vehicle Theft Security System (VTSS). In addition to low and high speed, the intermittent wipe system has a delay mode. Electronic circuitry within the intermittent wipe module is used to accomplish the wiper delay mode. The delay time selected by the driver has a range of from about one-half second to about fourteen seconds. The driver selects the length of the delay by placing the wiper (multi-function) switch knob in one of five different intermittent wipe detent positions. One of the detent positions sends a battery voltage signal to the intermittent wipe module, while the other four positions use resistors to provide progressively lower voltage signals to the module. If the washer knob is depressed while the wiper switch is in the Off position, the intermittent wipe module will operate the wiper motor for approximately two wipes and automatically turn off the motor. The intermittent wipe module is snap-fit onto a single blade-type mounting bracket located on the instrument panel reinforcement above the glove box opening. The intermittent wipe module cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 389 Wiper Control Module: Testing and Inspection Intermittent Wiper Module Testing The intermittent wipe module is used on vehicles that are not equipped with the Vehicle Theft Security System (VTSS). See Wiper System in the Diagnosis and Testing before performing the following tests. If the problem being diagnosed involves only some of the intermittent wipe delay positions, see Wiper Switch and Washer Switch in the Diagnosis and Testing. If the problem being diagnosed involves all of the intermittent wipe delay positions, proceed with the following tests. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Access and unplug the intermittent wipe module wire harness connector. Check for continuity between the ground circuit cavity of the intermittent wipe module wire harness connector and a good ground. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 2. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit of the intermittent wipe module wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit to the fuse in the junction block as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the wiper motor Check for continuity between the wiper park switch sense circuit (VS) cavities of the intermittent wipe module wire harness connector and the wiper motor wire harness connector. There should be continuity. If OK, go to Step 5. If not OK, repair the open circuit as required. 4. Unplug the steering column wire harness connector. Check for continuity between the wiper park switch sense circuit (V7) cavities of the intermittent wipe module wire harness connector and the instrument panel half of the steering column wire harness connector. There should be continuity. If OK, go to Step 6. If not OK, repair the open circuit as required. 5. Check for continuity between the wiper switch mode signal circuit cavities of the intermittent wipe module wire harness connector and the instrument panel half of the steering column wire harness connector. There should be continuity. If OK, go to Step 7. If not OK, repair the open circuit as required. 6. Check for continuity between the wiper switch delay output circuit cavities of the intermittent wipe module wire harness connector and the instrument panel half of the steering column wire harness connector. There should be continuity. If OK, go to Step 8. If not OK, repair the open circuit as required. 7. Test the multi-function switch continuity. See Wiper Switch and Washer Switch in the Diagnosis and Testing. If the switch tests OK, replace the faulty intermittent wipe module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 390 Wiper Control Module: Service and Repair Intermittent Wipe Module Replacement REMOVAL An intermittent wipe module is used on vehicles that are not equipped with the optional Vehicle Theft Security System (VTSS). See Intermittent Wipe Module and Central Timer Module in the Description and Operation for more information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Roll down the glove box from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Glove Box - Roll Down Replacement. Instermittent Wiper Module Remove/Install 3. Reach through and above the glove box opening to access the intermittent wipe module. Push the module towards the front of the vehicle to disengage the snap-fit slot on the intermittent wipe module from the slide tab of the mounting bracket on the instrument panel armature. 4. Lower the intermittent wipe module into the instrument panel glove box opening far enough to access and unplug the wire harness connector. 5. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams Wiper Relay: Diagrams Intermittent Wiper Relay Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 394 Wiper Relay: Description and Operation SYSTEM OPERATION An intermittent wipe relay is used on models that are equipped with the optional Vehicle Theft Security System (VTSS). The intermittent wipe relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The intermittent wipe relay is a electromechanical device that switches battery current to the windshield wiper motor when the relay coil is grounded by the Central Timer Module (CTM) in response to inputs from the windshield wiper (multi-function) switch. See Intermittent Wipe Relay in the Diagnosis. The intermittent wipe relay is located in a connector that is taped back to the instrument panel wire harness above the inboard side of the glove box opening. The intermittent wipe relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 395 Wiper Relay: Testing and Inspection The intermittent wipe relay is used on vehicles that are equipped with the Vehicle Theft Security System (VTSS). See Wiper System in the Diagnosis and Testing before performing the following tests. If the problem being diagnosed involves only some of the intermittent wipe delay positions, see Wiper Switch and Washer Switch in the Diagnosis and Testing. If the problem being diagnosed involves all of the intermittent wipe delay positions, proceed with the following tests. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Test Instrument Wipe Relay The intermittent wipe relay is located in a connector that is taped back to the instrument panel wire harness above the inboard side of the glove box opening in the passenger compartment. Remove the intermittent wipe relay from its wire harness connector as described Replacement to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the wiper (multi-function) switch. There should be continuity between the cavity for relay terminal 30 and the two washer switch output (V11A and V11B) circuit cavities in the instrument panel half of the steering column wire harness connector at all times. If OK, go to Step 3. If not OK, repair the open circuit(s) to the wiper (mufti-function) switch as a required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position. There should be continuity between the cavity for relay terminal 87A and the wiper park switch sense circuit cavities of the wiper motor wire harness connector and the 14-way Central Timer Module (CTM) wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit(s) to the wiper motor and CTM as required. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. There should be battery voltage at the cavity for relay terminal 87 with the ignition switch in the On or Accessory positions. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the junction block as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On or Accessory positions. If OK, go to Step 6. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded by the CTM to energize the relay and cycle the wiper motor. a Check for continuity between the cavity for relay terminal 85 and the intermittent wiper relay control circuit cavity of the 14-way CTM wire harness connector. There should be continuity If OK, use a DRB scan tool and the proper Diagnostic Procedures for diagnosis of the CTM. If not OK, repair the open circuit to the CTM as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 396 Wiper Relay: Service and Repair Intermittent Wipe Relay Replacement An intermittent wipe relay is used on vehicles that are equipped with the optional Vehicle Theft Security System (VTSS). See Intermittent Wipe Relay and Central Timer Module in the Description and Operation for more information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Roll down the glove box from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Glove Box - Roll Down Replacement. Intermittent Wipe Relay Remove/Install 3. Reach through and above the inboard side of the glove box opening to access the intermittent wipe relay. Remove the tape that secures the relay and its connector to the wire harness near the instrument panel armature. 4. Lower the intermittent wipe relay into the instrument panel glove box opening far enough to access and unplug the relay from its wire harness connector. 5. Install the intermittent wipe relay by aligning the relay terminals with the cavities in the wire harness connector and pushing the relay firmly into place. 6. Tape the intermittent wipe relay and its wire harness connector back to the wire harness. 7. Reinstall the glove box in the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Glove Box - Roll Down Replacement. 8. Connect the battery negative cable. 9. Test the relay operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams Door Disarm Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Page 402 Door Sensor/Switch (For Alarm): Description and Operation SYSTEM OPERATION Door Ajar Switch The door ajar switches are integra to the door latches on each front door. The door ajar switches for the side and rear doors are mounted to the door opening pillars. Each of these switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and open the ground path when a door is closed. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit (front doors) or door ajar switch unit (side or rear doors) must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Page 403 Door Sensor/Switch (For Alarm): Service and Repair REMOVAL Front Door The front door ajar switches are integral to the front door latch unit. If a front door ajar switch is faulty or damaged, the entire front door latch unit must be replaced. Side Or Rear Door 1. Disconnect and isolate the battery negative cable. Door Ajar Switch Remove/Install - Side Or Rear Door 2. Unscrew the door ajar switch from the pillar. 3. Pull the door ajar switch away from the pillar far enough to access and unplug the two wire harness connectors from the switch. 4. Remove the door ajar switch from the vehicle. 5. Reverse the removal procedures to install. Tighten the switch to 5.6 N.m (50 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Description and Operation Lock Cylinder Switch: Description and Operation SYSTEM OPERATION The door lock cylinder switches are mounted to the back of the key lock cylinder inside each front door. They are normally-open momentary witches that close to ground only when the lock cylinder is rotated to the unlock position. The door lock cylinder switches cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Description and Operation > Page 407 Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the front door. Door Lock Cylinder Switch Remove/Install 3. Unplug the door lock cylinder switch wire harness connector. 4. Disengage the door lock cylinder switch from the back of the front door lock cylinder 5. Disengage the retainers that secure the door lock cylinder switch wire harness to the inner door panel. 6. Remove the door lock cylinder switch from the door. 7. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 412 Power Door Lock Switch: Description and Operation SYSTEM OPERATION The power locks can be controlled by a two-way switch mounted in a bezel on the mirror flag bezel trim of each front door. The power lock switch controls the battery feeds to the lock and unlock sense inputs of the power lock and Remote Keyless Entry (RKE) module or the Central Timer Module (CTM). The relays that are integral to the power lock and REE module or the CTM then direct the correct battery and ground feeds to the power lock motors. The power lock switches cannot be repaired and, if faulty or damaged, the switches must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 413 Power Door Lock Switch: Testing and Inspection 1. Check the fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the power lock switch. 4. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power lock switch wire harness connector. If OK, go to Step 6. If not OK, repair the open circuit to the junction block as required. Power Lock Switch Continuity 5. Test the power lock switch continuity See the Power Lock Switch Continuity chart to determine if the continuity is correct in the Of,, Lock and Unlock switch positions. If OK, repair the door lock switch output (lock and/or unlock) circuit(s) from the power lock switch wire harness connector to the power lock and Remote Keyless Entry (RKE) module or to the Central Timer Module (CTM) as required. If not OK, replace the faulty switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 414 Power Door Lock Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the mirror flag bezel from the inside of the front door. Power Lock Switch Remove/Install 3. From the back side of the mirror flag bezel, remove the screws that secure the power window and power lock switch and mounting plate unit to the mirror flag bezel. 4. Remove the power window and power lock switch and mounting plate unit from the mirror flag bezel. 5. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power lock switch receptacle on the back of the switch mounting plate and pull the switch out of the receptacle. 6. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the switch mounting plate are fully engaged. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation SYSTEM OPERATION Power Mirror Switch Both the right and left power outside mirrors are controlled by a single multi-function switch unit located on and mounted to the upper flag area of the driver side door trim panel. The switch knob is rotated clockwise (right mirror control), or counterclockwise (left mirror control) to select the mirror to be adjusted. The switch knob is then moved in a joystick fashion to control movement of the selected mirror up, down, right, or left. The power mirror switch cannot be repaired and, if faulty or damaged, it must be replaced. The power mirror switch knob is available for service replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 418 Power Mirror Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Mirror Switch Knob Remove/Install 2. Pull the power mirror switch control knob rearward to remove it from the switch stem. Power Mirror Switch Nut 3. Remove the nut that secures the power mirror switch to the driver side door trim pane). 4. Remove the mirror flag bezel from the inside of the front door. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 419 Power Mirror Switch Remove/Install 5. Unplug the power mirror switch wire harness connector. 6. Remove the power mirror switch from the back of the door mirror flag bezel. 7. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation Power Seat Switch: Description and Operation SYSTEM OPERATION Power Seat Switch The power seat can be adjusted in six different ways using the power seat switch. The switch is located in a bezel on the lower inboard side of the seat cushion frame. on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch unit cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 423 Power Seat Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the seat cushion. See Power Seat Switch Replacement. Power Seat Switch Continuity 3. Use an ohmmeter to test the continuity of the switches in each position. See the Power Seat Switch Continuity chart. If OK, see Power Seat Adjuster and Motors in the Diagnosis and Testing. If not OK, replace the faulty switch module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 424 Power Seat Switch: Service and Repair REMOVAL 1. Remove the driver side front seat from the power seat adjuster and motors unit. See Power Seat Adjuster and Motors Replacement. Power Seat Switch And Bezel Remove/Install 2. Remove the two screws that secure the power seat switch and bezel unit to the seat from the inside of the seat cushion frame. 3. Pull the power seat switch and bezel unit out from the outside of the seat cushion frame far enough to access the wire harness connector. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the locking tabs of the power seat switch unit away from the wire harness connector and carefully unplug the switch from the connector. 5. Remove the two screws that secure the power seat switch unit to the back of the switch bezel. 6. Remove the power seat switch from the bezel. 7. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > 4WD Switch > Component Information > Description and Operation 4WD Switch: Description and Operation Vehicles equipped with four wheel drive (4WD) have an indicator switch mounted on the front axle assembly. This switch is closed to ground when the transfer case is shifted to four wheel drive mode and the engine is running on some vehicles. While in four wheel drive, the front and rear axles will operate together. With this input, the CAB is able to modify its operation to allow for 4WD operation. Should a need for antilock operation occur while in four wheel drive, the CAB will extend the amount of allowable dump cycles. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Description and Operation Braking Sensor/Switch: Description and Operation An input from this switch prepares the CAB for a possible antilock stop. The antilock system uses an input signal from the brake pedal activated switch. When the driver applies the brake pedal, the circuit voltage is 12 volts. A released brake pedal will close the switch circuit and provide O volts. This signal tells the CAB that the pedal is depressed Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > With Four Wheel Antilock Brakes Wheel Speed Sensor: Specifications Front Bolt 11 ft.lb Rear Bolt 18 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > With Four Wheel Antilock Brakes > Page 436 Wheel Speed Sensor: Specifications Mounting Bolt 18 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 439 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 440 Wheel Speed Sensor: Connector Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 443 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brakes OPERATION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front steering knuckles. The third sensor is mounted on top of the rear axle differential housing. The sensor is a magnet coil that is mounted over a tone wheel front/exciter ring rear with an air gap between them. The sensors measure the wheel speed by monitoring the rotation of the tone wheels front/exciter ring rear. As the teeth of the tone wheels front/exciter ring rear move through the magnetic field of the sensor an AC voltage is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The Controller Antilock Brake (CAB) monitors these signals for changes in wheel deceleration. If the CAB detects a sudden wheel or wheels deceleration within a predetermined amount the CAB will activate the ABS system. CIRCUIT OPERATION The all wheel Anti-Lock Brake System (ABS) uses three wheel speed sensors; a single sensor for both rear wheels and individual sensors for the front wheels. The single sensor used for the rear wheels mounts on the top of the rear axle differential housing. Each sensor converts wheel speed into an electrical signal that is transmitted to the Controller Anti-Lock Brakes (CAB). A pair of twisted wires connect to each sensor and provide signals to the CAB. Circuits B6 and B7 provide signals to the CAB from the right front wheel speed sensor. Circuit B6, which provides the LOW signal, connects to cavity 15 of the CAB. Circuit B7 connects to cavity 2 of the CAB and provides the HIGH signal. Circuits B8 and B9 provide signals to the CAB from the left front wheel speed sensor. Circuit B8, which provides the LOW signal, connects to cavity 16 of the CAB. Circuit B9 connects to cavity 3 and provides the HIGH signal. Circuit B114 connects to cavity 14 of the CAB and to circuit B2 of the rear wheel speed sensor harness at the sensor connector. Circuit B113 connects to cavity 1 of the CAB and to circuit B1 at the rear wheel speed sensor harness connector. Circuit B114 provides the rear wheel speed sensor LOW input while circuit B113 provides the HIGH input. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 446 Wheel Speed Sensor: Description and Operation Kelsey-Hayes Antilock Brake Systems The EBC 325 ABS system uses one wheel speed sensor on each front wheel, and one speed sensor mounted in the rear axle for the rear wheels. The RWAL II uses only one speed sensor mounted in the rear axle for the rear wheels. The sensor measures the wheel speed by monitoring a rotating tone wheel. The signal generated by the sensor and tone wheel is transmitted to the CAB. Each sensor has: - a metal tone wheel with teeth on its outside diameter - a magnetic/coil pick-up (speed sensor) that is mounted to a fixed component - an air gap between the tone wheel and the speed sensor assembly As the teeth of the tone wheel move through the magnetic field of the sensor, an AC voltage is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The CAB monitors this signal to check for a sudden change in single or multiple wheel decelerations. If the deceleration of one or more wheels is not within a predetermined amount, the antilock module takes control. Diagnostically, the coil of wheel speed sensors have different amounts of resistance based upon the sensor type. When measured across the connector two terminals, the resistance should be: AN, DN, BE and BR: 4x4 front sensors 945-1155 ohms AB, AN and DN: 4x2 front sensors 2500-2955 ohms BE and BR: 4x2 front sensors 1000-1250 ohms AB, AN, DN, BE and BR: All rear sensors 1600-2300 ohms NOTE: For all resistance ranges add 30% to the value for extreme heat, subtract 30% for extreme cold.) The rear wheel speed sensor used on all vehicles have the same resistance value, but there are two different sensors. Therefore, it is important to replace the rear wheel speed sensor with the proper part. On a EBC 325 system each front wheel speed is monitored through the speed sensor mounted at the wheel end of the hub. On a EBC 325 and RWAL II system the rear wheel speed is monitored through the speed sensor mounted in the rear axle assembly. The CAB will disable antilock control, illuminate the ABS warning light circuit via COD, and store trouble codes if it detects a problem with any or all of the wheel speed sensors: - incorrect circuit resistance when checked with no vehicle movement - incorrect sensor output during vehicle movement - erratic sensor output during vehicle movement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 447 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brakes The rear wheel speed sensor is mounted on the top of the rear axle differential. The sensor converts wheel speed into an electrical signal that is transmitted to the Rear Wheel Anti-Lock (RWAL) control module. Circuits B113 and B114, a pair of twisted wires connect to the sensor and provide signals to the RWAL control module. These circuits also connect to the rolls test connector used only during manufacture of the vehicle. Circuit B113 connects to cavity 14 of the RWAL control module and to circuit B1 of the wheel speed sensor harness. Circuit B114 connects to cavity 13 of the RWAL control module and circuit B2 of the sensor harness. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Front REMOVAL 1. Raise and support vehicle. 2. Disconnect speed sensor from the main harness. Wheel Speed Sensor 3. Remove sensor mounting bolt from the steering knuckle. 4. Remove the sensor from the steering knuckle. INSTALLATION CAUTION: A special bolt is used to attach the sensor. Use only a factory replacement bolt. 1. Install the sensor into the steering knuckle. 2. Install mounting bolt and tighten to 15 Nm (11 ft. lbs.). 3. Connect sensor wire to main harness and ensure wire is routed away from hot or moving components. 4. Remove supports and lower vehicle. With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 450 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 0-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. With Four Wheel Antilock Brakes REMOVAL 1. Raise and support vehicle. Rear Wheel Speed Sensor 2. Disconnect wire from rear sensor on axle housing. 3. Remove sensor and bracket mounting bolt and remove sensor and bracket. INSTALLATION 1. Secure sensor wire to rear brake hose with clips provided. 2. Install sensor and mounting bracket in axle housing. Install mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Connect wire to sensor and secure wire to mounting bracket. 4. Remove support and lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 451 Wheel Speed Sensor: Service and Repair Tone Wheel Replacement Front Tone Wheel Tone Wheel The tone wheel for the front speed sensor is located on the rotor hub. The tone wheel is not a serviceable component. The complete rotor and hub assembly will have to be replaced if the tone wheel is damaged. Rear Tone Wheel The toothed exciter ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, refer to Transmission and Drivetrain for service procedures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls ECT Sensor Test revisions NUMBER: 26-11-97F GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L/4.0L/5.2L/5.9L SFI Engine Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revisions to the ECT sensor voltage too high test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions > Page 458 165 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 459 Coolant Temperature Sensor/Switch (For Computer): Specifications Torque 11 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 460 Coolant Temperature Sensor/Switch (For Computer): Locations Generator, A/C Compressor, Elec.CONN, Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 461 Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 462 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Fig 1 Powertrain Control Module To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: 1. Vehicles equipped with air conditioning: a. Disconnect the negative battery cable at battery. b. Remove Jeep/Truck Engine Controller (JTEC) mounting bolts and remove JTEC. Do not disconnect three 32-way connectors from JTEC. Fig. 66 Engine Coolant Temperature Sensor 2. Disconnect wire harness connector from coolant temperature sensor. 3. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 463 Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 4. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 5. Test continuity of the wire harness between the JTEC wire harness connector and the coolant sensor connector terminals. - Refer to Diagrams/connector Views. - Repair the wire harness if an open circuit is indicated. 6. After tests are completed, connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 464 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING COOLANT TEMPERATURE SENSOR. Engine Coolant Temperature Sensor Location The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. 1. Disconnect negative battery cable at battery. 2. Place a small mirror above sensor connector. 3. Disconnect electrical connector from sensor. When removing connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place hook part of tool under connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Partially drain cooling system. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor into intake manifold. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. 5. Connect negative battery cable at battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Generator, A/C Compressor, Elec.CONN, Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Mounting Screws, Speed Control Switches Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 472 Speed Control Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 473 Cruise Control Switch: Description and Operation SYSTEM OPERATION Two separate speed control switch modules are mounted on the steering wheel to the left and right side of the driver's airbag module. Within the two switch modules, five momentary contact switches, supporting seven different speed control functions are used. The outputs from these switches are filtered into one input. The Powertrain Control Module (PCM) determines which output has been applied through resistive multiplexing. The input circuit voltage is measured by the PCM to determine which switch function has been selected. A speed control indicator lamp, located on the instrument panel cluster is energized by the PCM via the CCD Bus. This occurs when speed control system power has been turned ON, and the engine is running. The two switch modules are labeled: ON/OFF, SET, RESUME/ACCEL, CANCEL and COAST. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one individual switch fails, the switch module must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 474 Cruise Control Switch: Testing and Inspection For complete speed control system diagnosis, refer to the appropriate Powertrain Diagnostic Procedures. To test each of the speed control switches only, refer to the following: WARNING: BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL AND STEERING COLUMN COMPONENTS, YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT 2 MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect negative battery cable. Wait 2 minutes for airbag system capacitor to discharge. 2. Remove the two speed control switch modules from steering wheel. Refer to the removal/installation section for procedures. Speed Control Switch Continuity (Typical Switch Shown) 3. Check continuity of each individual speed control switch module as shown in chart. If OK, reinstall switch. If not OK, replace switch module assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 475 Cruise Control Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE INJURY. 1. Disconnect and isolate negative battery cable. 2. Remove airbag module. Refer to airbags Speed Control Switches 3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical connector at switch. INSTALLATION 1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to 1.5 N.m (14 in. lbs.) torque. 4. Install airbag module. Refer to airbags for procedures. 5. Connect negative battery cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Description and Operation Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation VEHICLE SPEED AND DISTANCE-PCM INPUT The Vehicle Speed Sensor (VSS) is no longer used for any Dodge truck in the 1998 model year. Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. See: Sensors and Switches - Brakes and Traction Control/Wheel Speed Sensor The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for fuel system and speed control system operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Service and Repair > With Four Wheel Antilock Brakes Vehicle Speed Sensor/Transducer - Cruise Control: Service and Repair With Four Wheel Antilock Brakes REMOVAL 1. Raise and support vehicle. Rear Wheel Speed Sensor 2. Disconnect wire from rear sensor on axle housing. 3. Remove sensor and bracket mounting bolt and remove sensor and bracket. INSTALLATION 1. Secure sensor wire to rear brake hose with clips provided. 2. Install sensor and mounting bracket in axle housing. Install mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Connect wire to sensor and secure wire to mounting bracket. 4. Remove support and lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Service and Repair > With Four Wheel Antilock Brakes > Page 481 Vehicle Speed Sensor/Transducer - Cruise Control: Service and Repair With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 0-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Transmission Wiring, Camshaft Position Connector, Distributor, Oilpressure Sending Unit/switch Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 486 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions Oil Pressure Sensor: Technical Service Bulletins Engine Controls/Fuel System - Manual Revisions NUMBER: 26-01-99C GROUP: Miscellaneous DATE: January, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Powertrain 2.5L. 3.9L, 5.2L, 5.9L, 8.0 SFI, Mechanical Injected Diesel Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revision to the Table of Contents Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 491 vi Revision to the Trouble Code Test menu Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 492 538 Revision to the Oil Pressure Sensor test 589, 589A through 589F Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 493 589 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 494 589A Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 495 589B Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 496 589C Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 497 589D Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 498 589E Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 499 589F Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation SYSTEM OPERATION Front The front blower motor is controlled by a four position rotary-type blower motor switch, mounted in the heater-only or heater-A/C control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned off by selecting the Off position with the heater-A/C mode control switch knob. The blower motor switch directs the blower motor ground path from the mode control switch to the blower motor resistor, or directly to ground through the high speed blower motor relay, as required to achieve the selected blower motor speed. The front blower motor switch cannot be repaired and, if faulty or damaged, the entire heater-only or heater-A/C control unit must be replaced. The blower motor switch knob is serviced separately Rear The optional rear heater-A/C unit blower motor is controlled by a four position rotary-type blower motor switch, mounted in the accessory switch plate located to the right of the heater-A/C control on the instrument panel. The switch allows the selection of one of three blower motor speeds and an Off position. The rear blower motor switch directs the blower motor ground path to the blower motor resistor, or directly to ground through the high speed blower motor relay as required to achieve the selected blower motor speed. The rear blower motor switch cannot be repaired and, if faulty or damaged, it must be replaced. The rear blower motor switch knob is serviced separately The rear blower motor switch also has a replaceable incandescent-type illumination lamp bulb. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 504 Blower Motor Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR-BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Front 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the heater-A/C control from the instrument panel. See Heater-A/C Control Replacement for the procedures. Check for continuity between the ground circuit (Z1V) cavity of the heater-A/C mode control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 2. With the heater-A/C control wire harness connector unplugged, place the heater-A/C mode control switch knob in any position except the Off position. Check for continuity between the two ground circuit terminals in the mode switch receptacle of the heater-A/C control. There should be continuity. If OK, go to Step 4. If not OK, replace the faulty heater-A/C control unit. 3. Check for continuity between the ground circuit (C 72) cavities of the heater-A/C mode control wire harness connector and the heater-A/C blower speed switch wire harness connector. There should be continuity. If OK, go to Step 5. If not OK, repair the open circuit as required. 4. Check for continuity between the ground circuit (C 72) terminal and each of the blower motor driver circuit terminals in the blower speed switch receptacle of the heater-A/C control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the heater-A/C control blower speed switch wire harness connector and the front blower motor resistor or the front high speed blower motor relay as required. If not OK, replace the faulty heater-A/C control unit. Rear 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the accessory switch plate from the instrument panel. Refer to Accessory Switch Plate in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel for the procedures. Check for continuity between the ground circuit cavity of the rear blower motor switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 2. With the rear blower motor switch wire harness connector unplugged, place the rear blower motor switch knob in any position except the Off position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the rear blower motor switch as you move the blower motor switch knob to each of the three speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the rear blower driver circuits between the rear blower motor switch wire harness connector and the rear blower motor resistor or the rear high speed blower motor relay as required. If not OK, replace the faulty rear blower motor switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 505 Blower Motor Switch: Service and Repair The rear blower motor switch is used only on models with the optional rear heater-A/C unit. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the accessory switch plate from the instrument panel. Refer to Accessory Switch Plate in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel procedures. Rear Blower Motor Remove/Install 3. Rotate the illumination lamp socket counterclockwise to disengage it from the back of the switch housing. 4. Pull the knob off of the blower motor switch stem from the front of the accessory switch plate. 5. With a small thin-bladed screwdriver, gently pry the sides of the accessory switch plate to release the two snap clips on each side of the rear blower motor switch housing. 6. Remove the rear blower motor switch from the back of the accessory switch plate. INSTALLATION 1. Position the rear blower motor switch on the back of the accessory switch plate. 2. Firmly and evenly press the rear blower motor switch into the back of the accessory switch plate until it snaps into place. Be certain that all of the switch snap clip retainers are fully engaged. 3. Reinstall the knob onto the rear blower motor switch stem from the front of the accessory switch plate. Be certain to index the flat on the switch stem with the flat in the hub of the knob. 4. Reinstall the illumination lamp socket to the back of the rear blower motor switch housing. 5. Reinstall the accessory switch plate in the instrument panel. Refer to Accessory Switch Plate in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel procedures. 6. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation High Pressure Sensor / Switch: Description and Operation SYSTEM OPERATION High Pressure Cut-Off Switch The high pressure cut-off switch is located on the discharge line near the condenser. The switch is screwed onto a fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The discharge line fitting is equipped with an 0-ring to seal the switch connection. The high pressure cut-off switch is connected in series electrically with the low pressure cut-off switch between the fin sensing cycling clutch switch and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch on and off. This prevents compressor operation when the discharge line pressure approaches high levels. The high pressure cut-off switch contacts are open when the discharge line pressure rises above about 3100 to 3375 kPa (450 to 490 psi). The switch contacts will close when the discharge line pressure drops to about 1860 to 2275 kPa (270 to 330 psi). The high pressure cut-off switch is a factory-calibrated unit. The switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Page 510 High Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the high pressure cut-off switch, verify that the refrigerant system has the correct refrigerant charge. See Refrigerant System Charge in the Service Procedures. 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the high pressure cut-off switch on the refrigerant system fitting. 3. Check for continuity between the two terminals of the high pressure cut-off switch. There should be continuity. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Page 511 High Pressure Sensor / Switch: Service and Repair REMOVAL High Pressure Cut-Off Switch Removed/Install 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the high pressure cut-off switch, which is mounted to a fitting on the discharge line between the compressor and the condenser inlet. 3. Unscrew the high pressure cut-off switch from the discharge line fitting. 4. Remove the high pressure cut-off switch from the vehicle. 5. Remove the 0-ring seal from the discharge line fitting and discard. INSTALLATION 1. Lubricate a new 0-ring seal with clean refrigerant oil and install it on the discharge line fitting. Use only the specified 0-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the high pressure cut-off switch on the discharge line fitting. Tighten the switch to 7.5 N.m (5.5 ft. lbs.). 3. Plug the wire harness connector into the high pressure cut-off switch. 4. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams 8w-80-4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 515 Low Pressure Sensor / Switch: Description and Operation SYSTEM OPERATION Fin Sensing Cycling Clutch Switch Fin Sensing Cycling Clutch Switch The fin sensing cycling clutch switch is used on this model to signal the Powertrain Control Module (PCM) to cycle the compressor clutch on arid off in order to control the evaporator temperature. Controlling the evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The fin sensing cycling clutch switch consists of a probe and a switch unit. The probe, which is a Negative Temperature Coefficient (NTC) thermistor in a capillary tube, is inserted between the front evaporator coil fins to monitor evaporator temperature. The switch unit contains internal control logic that monitors the input from the probe in order to switch an internal transistor that controls the output to the PCM. when the fin sensing cycling clutch switch sees a temperature input below about 1.60 °C (350 °F), it signals the PCM to cycle the compressor off. When the temperature input reaches above about 3.90 °C (390 °F), the switch signals the PCM to cycle the compressor back on. The fin sensing cycling clutch switch can be accessed for service by removing the screws and carefully lifting the front of the top cover up from the heater-A/C housing. The fin sensing cycling clutch switch is a sealed unit and cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Testing and Inspection > Fin Sensing Cycling Clutch Switch Low Pressure Sensor / Switch: Testing and Inspection Fin Sensing Cycling Clutch Switch Before testing the fin sensing cycling clutch switch, verity that the refrigerant system has the correct refrigerant charge. Also check that both the low and high pressure cut-off switches are functional, and confirm that the compressor clutch is operational. Use a volt/ohmmeter to test the switch. 1. Turn the ignition switch in the On position. Place the heater-A/C mode control switch in any A/C position. Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the fill sensing cycling clutch switch wire harness connector. If OK, go to Step 3. If not OK, repair the open circuit to the fuse in the junction block as required. 2. With the ambient temperature between 20 to 30° C (68 to 900 F), start the engine and run the air conditioning system. The compressor clutch should cycle on and off two to three times per minute. If the clutch fails to cycle at this rate in these temperatures, replace the faulty fin sensing cycling clutch switch. NOTE: If the ambient temperature is above 32° C (90° F) the compressor clutch may stay engaged and not cycle due to the high heat load. This condition is normal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Testing and Inspection > Fin Sensing Cycling Clutch Switch > Page 518 Low Pressure Sensor / Switch: Testing and Inspection Low Pressure Cut-Off Switch Before performing diagnosis of the low pressure cut-off switch, remember that lower ambient temperatures, below about -1° C (30° F), during cold weather will open the switch contacts and prevent compressor operation due to the pressure/temperature relationship of the refrigerant. Also verify that the refrigerant system has the correct refrigerant charge. See Refrigerant System Charge in the Service Procedures. 1. Disconnect and isolate the battery negative cable. 2. Unplug the low pressure cut-off switch wire harness connector from the switch on the suction line jumper fitting. 3. Install a jumper wire between the two cavities of the low pressure cut-off switch wire harness connector. 4. Connect a manifold gauge set to the refrigerant system service ports. See Refrigerant System Service Equipment and Refrigerant System Service Ports. 5. Connect the battery negative cable. 6. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 7. Check for continuity between the two terminals of the low pressure cut-off switch. There should be continuity with a suction pressure (low side) reading of 103 to 172 kPa (15 to 25 psi) or above, arid no continuity with a suction pressure reading of 48 to 90 kPa (7 to 13 psi) or below. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Fin Sensing Cycling Clutch Switch Replacement Low Pressure Sensor / Switch: Service and Repair Fin Sensing Cycling Clutch Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the screws that secure the top cover of the heater-A/C housing to the housing. 3. Unplug the wire harness connector from the fin sensing cycling clutch switch. Fin Sensing Cycling Clutch Switch Remove/Install 4. Carefully lift the front of the heater-A/C housing top cover far enough to access and remove the fin sensing cycling clutch switch probe from the evaporator coil fins. INSTALLATION 1. Carefully lift the heater-A/C housing top cover far enough to insert the fin sensing cycling clutch switch probe into the same hole between the evaporator coil fins from which it was removed. 2. Position the grommet on the fin sensing cycling clutch switch wire harness into the notch on the front edge of the lower heater-A/C housing. 3. Secure the top cover to the heater-A/C housing with the mounting screws. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 4. Plug in the fin sensing cycling clutch switch wire harness connector. 5. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Fin Sensing Cycling Clutch Switch Replacement > Page 521 Low Pressure Sensor / Switch: Service and Repair Low Pressure Cut-Out Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Low Pressure Cut-Off Switch Remove/Install 2. Unplug the wire harness connector from the low pressure cut-off switch on the suction line jumper near the filter-drier. 3. Unscrew the low pressure cut-off switch from the fitting on the suction line jumper. 4. Remove the 0-ring seal from the suction line jumper fitting and discard. INSTALLATION 1. Lubricate a new 0-ring seal with clean refrigerant oil and install it on the suction line jumper fitting. Use only the specified 0-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the low pressure cut-off switch on the suction line jumper fitting. Tighten the switch to 4 N.m (2.9 ft. lbs.). 3. Plug the wire harness connector into the low pressure cut-off switch. 4. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams Door Switch: Diagrams Left Front Door Ajar Switch Connector Right Front Door Ajar Switch Connector Auxiliary Door Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 526 Auxiliary Door Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions Fuel Gauge Sender: Technical Service Bulletins Engine Controls/Fuel System - Service Manual Revisions NUMBER: 26-12-97H GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L, 3.9L, 5.2L, 8.0L Powertrain Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the "No Cam Signal at PCM" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page 531 29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page 532 56 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page 533 58 Revision to the "Fuel Level Sending Unit" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page 534 412 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 535 Fuel Gauge Sender: Description and Operation DESCRIPTION The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a vanable resistor (track). The resistor track is used to send electrical signals to the Powertrain Control Module (PCM) for fuel gauge operation and for OBD II emission requirements. OPERATION For fuel gauge operation: As fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This increases the sending unit resistance causing the fuel gauge to read empty. After this fuel level signal is sent to the PCM, the PCM will transmit the data across the CCD bus circuits to the instrument panel. Here it is translated into the appropriate fuel gauge level reading. For OBD II emission monitor requirements: A voltage signal is sent from the resistor track on the sending unit to the PCM to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 536 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. To test the gauge sending unit only, it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal Installation for procedures. Measure the resistance across the sending unit terminals. With float in up position, resistance should be 20 ohms ± 6 ohms. - With float in down position, resistance should be 220 ± 6 ohms. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 537 Fuel Gauge Sender: Service and Repair Fig 30 Fuel Gauge Sending Unit Location The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located on top of fuel tank. REMOVAL 1. Remove fuel tank. 2. Remove fuel pump module. 3. Carefully separate the lower section of pump module from upper section by releasing three module lock tabs. Take care not to stretch plastic fuel line within module. 4. Unplug 6-way electrical connector. 5. Disconnect 2 sending unit wires at 6-way connector. Note location of wires within 6-way connector. Fig 31 Fuel Gauge Sending Lock Tab/Tracks 6. The sending unit is retained to pump module with a small lock tab and notch. Carefully pry up on lock tab to release from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 6-way connector. 4. Connect 6-way electrical connector to module. 5. Carefully connect lower section of pump module to upper section (3 tabs lock upper section to lower section). 6. Install fuel pump module. 7. Install fuel tank. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Lamp Switch Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 542 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > General Information Brake Light Switch: Description and Operation General Information SYSTEM OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is mounted on the brake pedal mounting bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > General Information > Page 545 Brake Light Switch: Description and Operation Switch With RWAL System The primary function of the switch,is to turn on the stop lamps during braking. The switch is also used to send signals to components that must know when the brakes are applied, such as the Powertrain Control Module (PCM), which uses the signal to cancel speed control. The Controller Antilock Brake (CAB) uses the brake switch signal to monitor brake pedal application. When the switch contacts open (brakes applied), the CAB receives the brake applied signal. The CAB then monitors the ABS system to anticipate the need for an ABS stop. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 546 Brake Light Switch: Testing and Inspection GENERAL INFORMATION Stop lamp switch operation can be tested with an ohmmeter. The ohmmeter is used to check continuity between the pin terminals at different plunger positions. NOTE: The switch wire harness must be disconnected before testing switch continuity. SWITCH CIRCUIT IDENTIFICATION Stop Lamp Switch Terminal Identification - Terminals 1 and 2 are for the RWAL/ABS module and Powertrain Control Module (PCM) circuit. - Terminals 5 and 6 are for the stop lamp circuit. - Terminals 3 and 4 are for the speed control circuit. SWITCH CONTINUITY TEST 1. Check continuity between terminal pins 5 and 6 as follows: a. Pull plunger all the way out to fully extended position. b. Attach test leads to pins 5 and 6 and note ohmmeter reading. c. If continuity exists, proceed to next test. Replace switch if meter indicates lack of continuity (shorted or open). 2. Check continuity between terminal pins 1 and 2 and pins 3 and 4 as follows: a. Push switch plunger inward to fully retracted position. b. Attach test leads to pins 1 and 2 and note ohmmeter reading. c. If continuity exists, switch is OK. Replace switch if meter indicates lack of continuity (switch is open). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 547 Brake Light Switch: Adjustments The switch can be adjusted by lightly pulling the brake pedal rearward against the internal booster stop. This will set the switch plunger to the proper position. CAUTION: Do not use excessive force to pull the pedal rearward. Excessive force will damage switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 548 Brake Light Switch: Service and Repair REMOVAL 1. Remove lower column cover. 2. Remove the Data Link Connector, hood release lever and park brake release lever from the knee blocker. 3. Remove the knee blocker for access to switch. 4. Press and hold brake pedal in applied position. Stop Lamp Switch Mounting 5. Rotate stop lamp switch counterclockwise about 1/16 turn to unlock switch. Then pull switch straight out of mounting bracket and release brake pedal. 6. If switch is to be tested or replaced, disconnect wire harness and remove switch from vehicle. INSTALLATION 1. Pull switch plunger all the way out. Then push plunger 4 notches inward to preset position. Plunger length out of housing will be approximately 14 mm (0.55 inch). 2. Plug wire harness connector into switch. 3. Press and hold brake pedal in applied position. 4. Align switch locking collar index in switch bracket. Then insert switch straight into bracket. 5. Turn switch clockwise about 1/16 turn to lock it in position. 6. Release brake pedal. 7. Lightly pull brake pedal rearward against internal stop in booster. CAUTION: Do not use excessive force to move the pedal rearward for switch adjustment. Excessive force will damage the switch. 8. Install the knee blocker. 9. Install the Data Link Connector, hood release lever and park brake release lever to the knee blocker. 10. Install lower column cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams Door Switch: Diagrams Left Front Door Ajar Switch Connector Right Front Door Ajar Switch Connector Auxiliary Door Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 552 Auxiliary Door Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Reach through and above the instrument panel glove box opening upper reinforcement to depress the retaining tabs on the top and bottom of the glove box lamp and switch housing. Glove Box Lamp And Switch Remove/Install 4. While holding the retaining tabs depressed, push the glove box lamp and switch unit out through the hole in the mounting tab on the upper instrument panel glove box opening. 5. Pull the glove box lamp and switch out through the mounting tab far enough to access and unplug the two wire harness connectors. 6. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation Hazard Warning Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch assembly, which is secured to the left side of the steering column. A switch stalk that extends from the left side of the multi-function switch is moved up or down to activate the right or left turn signals, respectively A latching push-button that extends upward from the multi-function switch and through the top of the upper steering column shroud is used to control the hazard warning system. The multi-function switch also contains circuitry for the following functions: Headlamp beam selection - Headlamp optical horn - Horn contact and circuit - Windshield wipers - Windshield washers. The information contained addresses only the multi-function switch turn signal and hazard warning switches. For information relative to the other circuits and switches that are integral to the multi-function switch. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit of the multi-function switch is faulty or damaged, the entire multi-function switch assembly must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 559 Hazard Warning Switch: Testing and Inspection The turn signal switch and the hazard warning switch are integral to the multi-function switch. See Turn Signal and Hazard Warning Systems in the Diagnosis and Testing before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Unplug the steering column wire harness connector. Turn Signal Switch And Hazard Warning Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the steering column half of the steering column wire harness connector terminals as shown in the Turn Signal Switch and Hazard Warning Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, repair the open circuit in the steering column wire harness or replace the faulty multi-function switch assembly as required. If the switches are OK, repair the lighting circuits as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 560 Hazard Warning Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. Refer to Airbag Module in the Removal and Installation for the procedures. 3. if the vehicle is equipped with the optional vehicle speed control, unplug the wire harness connectors from the speed control switches in the steering wheel. 4. Remove the nut that secures the steering wheel to the steering column upper shaft. 5. Remove the steering wheel with a steering wheel puller (Special Tool C-3428-B). 6. Remove the knee blocker from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Knee Diverter/Knee Blocker Replacement. 7. If the vehicle is so equipped, remove the tilt steering column lever by grasping the lever firmly and pulling it sharply away from the column. Lower Steering Column Shroud Screws 8. Remove the two screws from the bottom of the lower steering column shroud that secure it to the upper shroud. 9. Unsnap the front and both sides of the lower shroud from the upper shroud. Lower Steering Column Shroud Remove/Install 10. Tilt the lower shroud downward and slide it back to disengage the hooks from the pivots on the upper shroud. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 561 Upper Steering Column Shroud Remove/Install 11. Remove the two screws that secure the upper shroud to the steering column. 12. Remove the upper shroud from the steering column. Steering Column Tie-Wraps 13. Remove the two lower wire harness tie wraps. 14. Remove the screw from the center of the steering column wire harness connector and unplug the two halves of the connector. 15. Disengage the two multi-function switch wire harness connectors (one 17-way and one 13-way) from the steering column wire harness insulator. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 562 Multi-Function Switch Remove/Install 16. Remove the two screws that secure the multi-function switch to the steering column. 17. Remove the multi-function switch from the steering column. 18. Reverse the removal procedures to install. During installation, check that the following procedures are accomplished: - Tighten the multi-function switch mounting screws to 6 N.m (53 in. lbs.). - Be certain that the new wire harness tie-wraps are installed in the same positions as those that were removed. - Be certain that the steering column wire harnesses are routed so that they will not be pinched or stretched. - Be certain that the upper shroud spacer mounting stud is fully seated to the mounting boss on the inside of the shroud. - Tighten the upper shroud mounting screws to 1.4 N.m (12 in. lbs.). - Tighten the lower shroud mounting screws to 3.4 N.m (30 in. lbs.). - Be certain to index the alignment splines in the hub of the steering wheel with the splines on the upper steering column shaft. - Be certain to route the wire harnesses from the clockspring between the steering wheel back trim cover and the steering wheel armature. - Tighten the steering wheel nut to 61 N.m (45 ft. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Headlamp Switch Connector Headlamp Switch Ground Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 566 Headlamp Switch: Testing and Inspection Headlamp Diagnosis When a vehicle experiences problems with the headlamp system, verify the condition of the battery connections, charging system, headlamp bulbs, wire connectors, relay, high beam dimmer switch and headlamp switch. Always begin any diagnosis by testing all of the fuses and circuit breakers in the system. Conventional and halogen headlamps are interchangeable. It is recommended that they not be intermixed on a given vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 567 Headlamp Switch: Service and Repair WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - IF THE HEADLAMP SWITCH WAS ON, WAIT FIVE MINUTES TO ALLOW THE CERAMIC DIMMER RESISTOR TO COOL. IF THE CERAMIC DIMMER RESISTOR IS NOT ALLOWED TO COOL, IT CAN BURN YOUR FINGERS. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. See Cluster Bezel Replacement for the procedures. 3. Remove the three screws that secure the headlamp switch bezel to the instrument panel. Headlamp Switch And Bezel Remove/Install 4. Pull the headlamp switch and bezel out from the instrument panel far enough to access and unplug the wire harness connectors. 5. Pull the headlamp switch control knob out to the On position stop. 6. Depress the headlamp switch knob and shaft release button on the top of the switch. 7. While holding the release button depressed, pull the knob and shaft out of the headlamp switch. 8. Remove the spanner nut that secures the headlamp switch bezel and mounting bracket to the switch. 9. Remove the headlamp switch bezel and mounting bracket from the switch. 10. Reverse the removal procedures to install. Tighten the headlamp switch and bezel mounting screws to 2.2 N.m (20 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Horn Switch: Locations A center-blow, resistive membrane-type horn switch is installed on the back side of the driver side airbag module trim cover in the center of the steering wheel. When the center area of the airbag trim cover is depressed, the horn switch completes a curcuit to ground for the coil side of the horn relay. The steering wheel and steering column must be properly grounded for the horn switch to function. The horn switch is only serviced as a part of the airbag module trim cover. If the horn switch should fail, or if the airbag is deployed, the airbag module trim cover and horn switch must be replaced as a unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 571 Horn Switch: Description and Operation SYSTEM OPERATION A center-blow, resistive membrane-type horn switch is installed on the back side of the driver side airbag module trim cover in the center of the steering wheel. When the center area of the airbag trim cover is depressed, the horn switch completes a circuit to ground for the coil side of the horn relay. The steering wheel and steering column must be properly grounded for the horn switch to function. The horn switch is only serviced as a part of the airbag module trim cover. If the horn switch should fail, or if the airbag is deployed, the airbag module trim cover and horn switch must be replaced as a unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 572 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover and knee blocker from the instrument panel. 2. Check for continuity between the metal steering column jacket and a good ground. There should be continuity. If OK, go to Step 4. If not OK, refer to Steering and Suspension/Steering Column. 3. Remove the driver side airbag module from the steering wheel. Refer to Airbag Module in Air Bags and Seat Belts/Air Bags for the procedures. Unplug the horn switch wire harness connector from the air-bag module. 4. Unplug the horn relay from the junction block. Check for continuity between the steering column half of the horn switch feed wire harness connector and a good ground. There should be no continuity If OK, go to Step 6. If not OK, see Horn Contact in the Diagnosis and Testing. 5. Check for continuity between the steering column half of the horn switch feed wire harness connector and the horn relay control circuit cavity for the horn relay in the PDC. There should be continuity If OK, go to Step 7. If not OK, see Horn Tower in the Diagnosis and Testing. 6. Check for continuity between the horn switch feed wire and the horn switch ground wire on the airbag module. There should be no continuity. If OK, go to Step 8. If not OK, replace the faulty horn switch. 7. Depress the center of the airbag module trim cover and check for continuity between the horn switch feed wire and the horn switch ground wire on the airbag module. There should now be continuity If not OK, replace the faulty horn switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Driver Side Airbag Trim Cover and Horn Switch Horn Switch: Service and Repair Driver Side Airbag Trim Cover and Horn Switch REMOVAL WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE HORN SWITCH IS INTEGRAL TO THE AIRBAG MODULE TRIM COVER. SERVICE OF THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the driver side airbag module from the steering wheel. See Airbag Module - Driver Side in the Replacement. Airbag Trim Cover Retainer Nuts Remove/Install 3. Remove the four nuts that secure the upper and lower trim cover retainers to the studs on the airbag housing. Airbag Trim Cover Retainers Remove/Install 4. Remove the upper and lower trim cover retainers from the airbag housing studs. 5. Remove the horn switch ground wire eyelet from the airbag housing stud. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Driver Side Airbag Trim Cover and Horn Switch > Page 575 Airbag Trim Cover Remove/Install 6. Disengage the six trim cover locking blocks from the lip around the outside edge of the airbag housing and remove the housing from the cover. WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE DRIVER SIDE AIRBAG MODULE TRIM COVER AND THE DRIVER SIDE AIRBAG MODULE. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. 7. When installing the trim cover and horn switch, be certain that the locking blocks are fully engaged on the lip of the airbag housing. Driver Side Airbag Trim Cover Locking Blocks Engaged 8. When installing the upper and lower trim cover retainers, be certain that the tabs on each retainer are engaged in the retainer slots of the trim cover. 9. Install and tighten the trim cover retainer nuts to 10 N.m (90 in. lbs.). 10. Reverse the remaining removal procedures to complete the installation, but do not connect the battery negative cable at this time. See Airbag System in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Driver Side Airbag Trim Cover and Horn Switch > Page 576 Horn Switch: Service and Repair Horn Switch REMOVAL AND INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH A DRIVER SIDE AIRBAG, THE HORN SWITCH IS INTEGRAL TO THE AIRBAG MODULE TRIM COVER. SERVICE OF THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REFER TO DRIVER SIDE AIR-BAG TRIM COVER AND HORN SWITCH IN THE REMOVAL AND INSTALLATION SECTION OF AIRBAG FOR THE SERVICE PROCEDURES . Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams Courtesy Lamp Defeat Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Description and Operation Turn Signal Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch assembly, which is secured to the left side of the steering column. A switch stalk that extends from the left side of the multi-function switch is moved up or down to activate the right or left turn signals, respectively A latching push-button that extends upward from the multi-function switch and through the top of the upper steering column shroud is used to control the hazard warning system. The multi-function switch also contains circuitry for the following functions: Headlamp beam selection - Headlamp optical horn - Horn contact and circuit - Windshield wipers - Windshield washers. The information contained addresses only the multi-function switch turn signal and hazard warning switches. For information relative to the other circuits and switches that are integral to the multi-function switch. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit of the multi-function switch is faulty or damaged, the entire multi-function switch assembly must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Description and Operation > Page 583 Turn Signal Switch: Testing and Inspection Turn Signal Switch and Hazard Warning Switch The turn signal switch and the hazard warning switch are integral to the multi-function switch. See Turn Signal and Hazard Warning Systems in the Diagnosis and Testing before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Unplug the steering column wire harness connector. Turn Signal Switch And Hazard Warning Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the steering column half of the steering column wire harness connector terminals as shown in the Turn Signal Switch and Hazard Warning Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, repair the open circuit in the steering column wire harness or replace the faulty multi-function switch assembly as required. If the switches are OK, repair the lighting circuits as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Description and Operation > Page 584 Turn Signal Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. Refer to Airbag Module in the Removal and Installation for the procedures. 3. if the vehicle is equipped with the optional vehicle speed control, unplug the wire harness connectors from the speed control switches in the steering wheel. 4. Remove the nut that secures the steering wheel to the steering column upper shaft. 5. Remove the steering wheel with a steering wheel puller (Special Tool C-3428-B). 6. Remove the knee blocker from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Knee Diverter/Knee Blocker Replacement. 7. If the vehicle is so equipped, remove the tilt steering column lever by grasping the lever firmly and pulling it sharply away from the column. Lower Steering Column Shroud Screws 8. Remove the two screws from the bottom of the lower steering column shroud that secure it to the upper shroud. 9. Unsnap the front and both sides of the lower shroud from the upper shroud. Lower Steering Column Shroud Remove/Install 10. Tilt the lower shroud downward and slide it back to disengage the hooks from the pivots on the upper shroud. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Description and Operation > Page 585 Upper Steering Column Shroud Remove/Install 11. Remove the two screws that secure the upper shroud to the steering column. 12. Remove the upper shroud from the steering column. Steering Column Tie-Wraps 13. Remove the two lower wire harness tie wraps. 14. Remove the screw from the center of the steering column wire harness connector and unplug the two halves of the connector. 15. Disengage the two multi-function switch wire harness connectors (one 17-way and one 13-way) from the steering column wire harness insulator. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Description and Operation > Page 586 Multi-Function Switch Remove/Install 16. Remove the two screws that secure the multi-function switch to the steering column. 17. Remove the multi-function switch from the steering column. 18. Reverse the removal procedures to install. During installation, check that the following procedures are accomplished: - Tighten the multi-function switch mounting screws to 6 N.m (53 in. lbs.). - Be certain that the new wire harness tie-wraps are installed in the same positions as those that were removed. - Be certain that the steering column wire harnesses are routed so that they will not be pinched or stretched. - Be certain that the upper shroud spacer mounting stud is fully seated to the mounting boss on the inside of the shroud. - Tighten the upper shroud mounting screws to 1.4 N.m (12 in. lbs.). - Tighten the lower shroud mounting screws to 3.4 N.m (30 in. lbs.). - Be certain to index the alignment splines in the hub of the steering wheel with the splines on the upper steering column shaft. - Be certain to route the wire harnesses from the clockspring between the steering wheel back trim cover and the steering wheel armature. - Tighten the steering wheel nut to 61 N.m (45 ft. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Tray, Battery Tempt Sensor, Engine Wiring Harness, Sensor Harness Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 592 Battery Temperature Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 593 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 594 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry. refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pig-tail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 597 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. Refer to Starting and Charging/Battery 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Refer to Starting and Charging/Battery Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 601 Camshaft Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 602 Camshaft Position Sensor: Description and Operation SYSTEM OPERATION The camshaft position sensor is located in the distributor on all engines. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 603 Camshaft Position Sensor: Testing and Inspection Camshaft Position Sensor - Typical The camshaft position sensor is located in the distributor on all engines. To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostics Procedures service. To test the sensor only, refer to the following: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Remove engine cover. 2. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. For wire identification. 3. Connect the negative (-) voltmeter lead into the ground wire. For wire identification. 4. Set the voltmeter to the 15 Volt DC scale. 5. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 6. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 7. If voltage is not present, check the voltmeter leads for a good connection. 8. If voltage is still not present, check for voltage at the supply wire. For wire identification. 9. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 10. If voltage is still not present, perform vehicle test using the DRB scan tool. 11. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM. If continuity is not present, repair the harness as necessary c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 12. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 604 Camshaft Position Sensor: Service and Repair The camshaft position sensor is located in the distributor. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove engine cover. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. Crankshaft Position Sensor 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls ECT Sensor Test revisions NUMBER: 26-11-97F GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L/4.0L/5.2L/5.9L SFI Engine Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revisions to the ECT sensor voltage too high test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions > Page 609 165 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 610 Coolant Temperature Sensor/Switch (For Computer): Specifications Torque 11 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 611 Coolant Temperature Sensor/Switch (For Computer): Locations Generator, A/C Compressor, Elec.CONN, Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 612 Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 613 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Fig 1 Powertrain Control Module To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: 1. Vehicles equipped with air conditioning: a. Disconnect the negative battery cable at battery. b. Remove Jeep/Truck Engine Controller (JTEC) mounting bolts and remove JTEC. Do not disconnect three 32-way connectors from JTEC. Fig. 66 Engine Coolant Temperature Sensor 2. Disconnect wire harness connector from coolant temperature sensor. 3. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 614 Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 4. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 5. Test continuity of the wire harness between the JTEC wire harness connector and the coolant sensor connector terminals. - Refer to Diagrams/connector Views. - Repair the wire harness if an open circuit is indicated. 6. After tests are completed, connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 615 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING COOLANT TEMPERATURE SENSOR. Engine Coolant Temperature Sensor Location The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. 1. Disconnect negative battery cable at battery. 2. Place a small mirror above sensor connector. 3. Disconnect electrical connector from sensor. When removing connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place hook part of tool under connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Partially drain cooling system. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor into intake manifold. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. 5. Connect negative battery cable at battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Mounting Bolts 8 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 619 Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 620 Crankshaft Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 621 Crankshaft Position Sensor: Description and Operation SYSTEM OPERATION Sensor Operation Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. On this engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 622 Crankshaft Position Sensor: Testing and Inspection To perform a complete test of this sensor and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 623 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor - Typical The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. 1. Remove engine cover. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 N.m (70 in.lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications IAT Sensor IAT Sensor Torque 28 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 627 Intake Air Temperature Sensor: Locations Intake Manifold Air TEMPT Sensor, Electrical CONN Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 628 Intake Air TEMPT Sensor CONN Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 629 Intake Air Temperature Sensor: Testing and Inspection Fig. 69 Intake Manifold Air Temperature Sensor 1. Disconnect the wire harness connector from the intake manifold air temperature sensor. Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. Refer to the Coolant Temperature sensor/Intake Air Temperature sensor resistance chart. Replace the sensor if it is not within the range of resistance specified in the chart. 3. Test the resistance of the wire harness. Do this between the Powertrain Control Module (PCM) wire harness connector A-15 and the sensor connector terminal. Also check between PCM connector A-4 to the sensor connector terminal. Repair the wire harness as necessary if the resistance is greater than 1 ohm. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 630 Intake Air Temperature Sensor: Service and Repair Fig 57 Air Temperature Sensor REMOVAL 1. Disconnect electrical connector at sensor. 2. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 N.m (20 ft. lbs.) torque. 2. Install electrical connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Mounting Screws 3 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 634 Manifold Pressure/Vacuum Sensor: Locations Fig. 15 MAP And Throttle Position Sensor Location - Typical Map Sensor, Idle Air Control Motor, Throttle Position Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 635 Map Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 636 Manifold Pressure/Vacuum Sensor: Testing and Inspection Fig 57 Manifold Absolute Pressure Sensor 1. Inspect the rubber L-shaped fitting from the Manifold Absolute Pressure (MAP) sensor to the throttle body. Repair as necessary. CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. Fig 58 Rubber L-Shaped Fitting -- MAP Sensor-to-Throttle Body Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 637 Fig 33 MAP Sensor Connector Terminals -- Typical 2. Test the MAP sensor output voltage at the MAP sensor connector between terminals A and B. With the ignition switch ON and the engine OFF, output voltage should be 4-to-5 volts. The voltage should drop to 1.5-to-2.1 volts with a hot, neutral idle speed condition. 3. Test Powertrain Control Module (PCM) cavity A-27 for the same voltage described above to verify the wire harness condition. Repair as necessary. 4. Test MAP sensor supply voltage at sensor connector between terminals A and C with the ignition ON. The voltage should be approximately 5 volts (+/- 0.5V). Five volts (+/- 0.5V) should also be at cavity A-17 of the PCM wire harness connector. Repair or replace the wire harness as necessary 5. Test the MAP sensor ground circuit at sensor connector terminal-A and PCM connector A-4. Repair the wire harness if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 638 Manifold Pressure/Vacuum Sensor: Service and Repair Fig 86 MAP Sensor Location The Manifold Absolute Pressure (MAP) sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. NOTE: The throttle body must be removed from the intake manifold for MAP sensor removal. REMOVAL 1. Remove air cleaner assembly. 2. Remove throttle body. 3. Remove two MAP sensor mounting bolts (screws). 4. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body 5. Remove rubber L-shaped fitting from MAP sensor. Fig 87 MAP Sensor L-Shaped Rubber Fitting INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 N.m (25 in. lbs.) torque. 4. Install throttle body. 5. Install air cleaner. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions Oil Pressure Sensor: Technical Service Bulletins Engine Controls/Fuel System - Manual Revisions NUMBER: 26-01-99C GROUP: Miscellaneous DATE: January, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Powertrain 2.5L. 3.9L, 5.2L, 5.9L, 8.0 SFI, Mechanical Injected Diesel Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revision to the Table of Contents Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 643 vi Revision to the Trouble Code Test menu Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 644 538 Revision to the Oil Pressure Sensor test 589, 589A through 589F Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 645 589 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 646 589A Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 647 589B Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 648 589C Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 649 589D Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 650 589E Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 651 589F Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Torque 30 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 657 JTEC O2 Sensor Location Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 658 Oxygen Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 659 Oxygen Sensor: Application and ID Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 660 Oxygen Sensor: Testing and Inspection Fig 6 Heated Oxygen Sensors The upstream O2S sensor is located on the inlet end of the catalytic converter. The downstream O2S sensor is located on the outlet end of the catalytic converter. Each O2S heating element can be tested with an ohmmeter as follows: Disconnect the O2S sensor connector. Connect the ohmmeter test leads across the white wire terminals of the sensor connector. Resistance should be between 4 and 7 ohms. Replace the sensor if the ohmmeter displays an infinity (open) reading. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 661 Oxygen Sensor: Service and Repair Fig 6 Heated Oxygen Sensors NOTE: The O2S sensors are located at the inlet and outlet ends of the catalytic converter. WARNING: The exhaust manifold, exhaust pipes and catalytic converter become very hot during engine operation. Allow engine to cool before removing oxygen sensor. REMOVAL 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. NOTE: Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. INSTALLATION 1. Install the O2S sensor. Tighten to 30 N.m (22 ft. lbs.) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions Throttle Position Sensor: Technical Service Bulletins Fuel System/Engine Controls - Manual Revisions NUMBER: 26-02-99A GROUP: Miscellaneous DATE: February, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revision to the Diagnostic Trouble Codes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 666 45 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 667 46 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 668 47 Revision to the Throttle Position Sensor connector pin outs Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 669 152 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 670 156 Revision to the Fuel System Rich test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 671 316 Revisions to the Throttle Position sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 672 620 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 673 622 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 674 Throttle Position Sensor: Specifications Mounting Screws 7 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 675 Throttle Position Sensor: Locations Map Sensor Throttle Position Sensor, Idle Air Control Motor, Throttle Position Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 676 Throttle Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 677 Throttle Position Sensor: Testing and Inspection The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). - At idle, TPS output voltage should should be greater than 0.350 millivolts and less than 900 millivolts. - At wide open throttle, TPS output voltage must be less than 4.5 volts. - The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. NOTE: For additional testing information and circuit diagnosis see Computers and Control Systems/System Diagnosis/Procedures/Diagnostic Charts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 678 Throttle Position Sensor: Service and Repair Fig 80 TPS Mounting Bolts REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body Fig. 81 Installation INSTALLATION The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 682 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 687 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 688 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 689 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 690 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 691 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 692 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 693 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 694 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 695 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 696 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 697 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 698 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 699 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 700 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 701 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 702 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 703 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 704 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 705 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED AND DISTANCE-PCM INPUT The Vehicle Speed Sensor (VSS) is no longer used for any Dodge truck in the 1998 model year. Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. See: Sensors and Switches - Brakes and Traction Control/Wheel Speed Sensor The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for fuel system and speed control system operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > With Four Wheel Antilock Brakes Vehicle Speed Sensor: Service and Repair With Four Wheel Antilock Brakes REMOVAL 1. Raise and support vehicle. Rear Wheel Speed Sensor 2. Disconnect wire from rear sensor on axle housing. 3. Remove sensor and bracket mounting bolt and remove sensor and bracket. INSTALLATION 1. Secure sensor wire to rear brake hose with clips provided. 2. Install sensor and mounting bracket in axle housing. Install mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Connect wire to sensor and secure wire to mounting bracket. 4. Remove support and lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > With Four Wheel Antilock Brakes > Page 708 Vehicle Speed Sensor: Service and Repair With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 0-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions Throttle Position Sensor: Technical Service Bulletins Fuel System/Engine Controls - Manual Revisions NUMBER: 26-02-99A GROUP: Miscellaneous DATE: February, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revision to the Diagnostic Trouble Codes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 714 45 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 715 46 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 716 47 Revision to the Throttle Position Sensor connector pin outs Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 717 152 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 718 156 Revision to the Fuel System Rich test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 719 316 Revisions to the Throttle Position sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 720 620 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 721 622 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 722 Throttle Position Sensor: Specifications Mounting Screws 7 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 723 Throttle Position Sensor: Locations Map Sensor Throttle Position Sensor, Idle Air Control Motor, Throttle Position Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 724 Throttle Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 725 Throttle Position Sensor: Testing and Inspection The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). - At idle, TPS output voltage should should be greater than 0.350 millivolts and less than 900 millivolts. - At wide open throttle, TPS output voltage must be less than 4.5 volts. - The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. NOTE: For additional testing information and circuit diagnosis see Computers and Control Systems/System Diagnosis/Procedures/Diagnostic Charts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 726 Throttle Position Sensor: Service and Repair Fig 80 TPS Mounting Bolts REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body Fig. 81 Installation INSTALLATION The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 731 Camshaft Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 732 Camshaft Position Sensor: Description and Operation SYSTEM OPERATION The camshaft position sensor is located in the distributor on all engines. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 733 Camshaft Position Sensor: Testing and Inspection Camshaft Position Sensor - Typical The camshaft position sensor is located in the distributor on all engines. To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostics Procedures service. To test the sensor only, refer to the following: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Remove engine cover. 2. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. For wire identification. 3. Connect the negative (-) voltmeter lead into the ground wire. For wire identification. 4. Set the voltmeter to the 15 Volt DC scale. 5. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 6. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 7. If voltage is not present, check the voltmeter leads for a good connection. 8. If voltage is still not present, check for voltage at the supply wire. For wire identification. 9. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 10. If voltage is still not present, perform vehicle test using the DRB scan tool. 11. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM. If continuity is not present, repair the harness as necessary c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 12. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 734 Camshaft Position Sensor: Service and Repair The camshaft position sensor is located in the distributor. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove engine cover. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. Crankshaft Position Sensor 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Mounting Bolts 8 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 738 Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 739 Crankshaft Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 740 Crankshaft Position Sensor: Description and Operation SYSTEM OPERATION Sensor Operation Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. On this engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 741 Crankshaft Position Sensor: Testing and Inspection To perform a complete test of this sensor and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 742 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor - Typical The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. 1. Remove engine cover. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 N.m (70 in.lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For electrical diagnosis of the Key-In-Switch, For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Replacement. On vehicles equipped with an automatic transmission and a steering column mounted shifter, an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. On vehicles equipped with an automatic transmission and a floor mounted shifter, a cable connects the interlock device within the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. The shifter interlock cable can be adjusted or replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 747 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative battery cable from battery. 2. Place shifter in PARK position. 3. Remove tilt-wheel lever (pulls out). Lower Shroud Screws 4. Remove 2 lower shroud screws (size T25). Shroud Pivot Point 5. Upper and lower shrouds are snapped together at sides. Pivot points for lower and upper shrouds is at rear of shrouds. Lower shroud is hooked to pins on upper shroud. Tilt lower shroud down for removal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 748 Upper Shroud Screws 6. Remove 2 upper shroud screws (size T5) and remove upper shroud from steering column. 7. If removing key lock cylinder only, proceed to next step. If removing ignition switch, proceed to IGNITION SWITCH REMOVAL. 8. KEY LOCK CYLINDER REMOVAL: Ignition key must be in key cylinder for cylinder removal. a. Rotate and hold key in START position. Lock Cylinder Retainer Pin Access Hole b. Position a 1/16" pin punch into lock cylinder retainer pin access hole. c. Press in on pin punch to release lock cylinder retainer pin while releasing key to RUN position. d. Pull lock cylinder out for removal. 9. IGNITION SWITCH REMOVAL: Key lock cylinder removal is not necessary for ignition switch removal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 749 Installing Lock Cylinder To Column Removing/Installing Alarm Switch a. Remove alarm switch. Alarm switch is located at right/upper side of steering column. Press on retaining clip with a small screwdriver while rotating switch 1/4 turn for removal. b. Remove knee blocker below steering column. Refer to Knee Blocker in Instrument Panel Gauges And Warning Indicator. c. Note position of wiring harnesses and all tie wraps between ignition switch and 4 way connector at lower part of steering column. when installing ignition switch/wire harness assembly, the harnesses must be correctly routed with tie wraps in correct position to prevent damage to harness. d. If equipped with overdrive (OD) transmission, unclip OD wire harness at ignition switch. e. Cut necessary tie wraps. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 750 Ignition Switch Mounting Screws f. Remove 2 ignition switch mounting screws (size T4) and separate switch at steering column. Separating 48-Way Connectors At Lower Part Of Column g. Separate steering column 48-way electrical connectors by removing one fastener (bolt). The 48-way connector is located near lower part of steering column. This 48-way connector contains 48 different pin-outs including 3 different connectors: a 17-way for the multi-function switch; a 13-way for the multi-function switch; and an 18-way for the ignition switch. Separating 48-Way Connectors At Lower Part Of Column h. Separate 17-way multi-function switch connector from 18-way ignition switch connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 751 Steering Column 48-Way Connector (Male C0nnector To Column Shown) i. Separate 13-way multi-function switch connector from 18-way ignition switch connector. j. Separate multi-function switch wire harnesses from ignition switch wiring harness. k. Remove wiring harness and ignition switch as an assembly from steering column. INSTALLATION 1. KEY LOCK CYLINDER INSTALLATION: a. Place key into lock cylinder. b. Place key lock cylinder into steering column by aligning positioning tab on lock cylinder to positioning slot on steering column. Locking tab should also be aligned to locking tab slot. c. Press on lock cylinder until retaining pin engages. d. Rotate key to OFF position. e. Check for proper retention of lock cylinder by attempting to pull out on lock cylinder. 2. IGNITION SWITCH INSTALLATION: a. Position switch and wire harness assembly to steering column. b. Install switch screws and tighten to 1.4 N.m (12 in. lbs.) torque. c. Carefully route ignition switch wire harness down to bottom of steering column. d. If equipped with overdrive (OD) transmission, clip OD wire harness to ignition switch. e. Route alarm switch wire harness around ignition switch. f. Attach alarm switch to steering column by rotating and snapping into position). g. Attach 13-way multi-function switch connector to ignition switch 18-way connector. h. Attach 17-way multi-function switch connector to ignition switch 18-way connector. i. Attach both 48-way electrical connectors together (1 bolt). Tighten bolt to 7 N.m (62 in. lbs.) torque. j. Install new tie wraps in their previously noted positions. k. If equipped with a tilt steering wheel, operate tilt mechanism while observing wiring harnesses for binding. Correct binding if necessary. l. Operate shift lever while observing wiring harnesses for binding. Correct binding if necessary. 3. A 2-5/8" long plastic spacer is attached to inside of upper shroud. Before positioning shroud to column, verify spacer is tightened to upper shroud. 4. Position upper shroud to steering column. 5. Install 2 upper shroud screws. 6. Position rubber shields for shift lever and multi-function switch into upper shroud. 7. Position lower shroud hooks into pins on upper shroud. 8. Snap lower shroud to upper shroud. 9. Install 2 lower shroud screws. 10. Install tilt-wheel lever (snaps in). 11. Shifter should lock in PARK position when key is in LOCK position. Shifter should unlock when key rotated to ON position. 12. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 13. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify Steering wheel should unlock when key is rotated to ON position. 14. Connect negative battery cable to battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 757 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 758 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 759 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 760 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 761 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 762 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 763 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 764 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 765 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 766 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 767 PARTS REQUIRED: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 768 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 769 POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations Passenger Airbag Switch Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations > Page 772 Passenger Side Airbag On/Off Switch Remove/Install Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 773 Air Bag Deactivation Switch: Diagrams Passenger Airbag Switch Connector Passenger Airbag Switch Connector Passenger Airbag Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 774 Air Bag Deactivation Switch: Service and Repair REMOVAL WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the accessory switch plate from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Accessory Switch Plate Replacement. Passenger Side Airbag On/Off Switch Remove/Install 3. Remove the two screws that secure the passenger airbag disarm switch to the back of the accessory switch plate. 4. Remove the passenger airbag disarm switch from the accessory switch plate. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 6. Do not connect the battery negative cable at this time. See Airbag System in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Tray, Battery Tempt Sensor, Engine Wiring Harness, Sensor Harness Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 779 Battery Temperature Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 780 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 781 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry. refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pig-tail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 784 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. Refer to Starting and Charging/Battery 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Refer to Starting and Charging/Battery Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For electrical diagnosis of the Key-In-Switch, For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Replacement. On vehicles equipped with an automatic transmission and a steering column mounted shifter, an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. On vehicles equipped with an automatic transmission and a floor mounted shifter, a cable connects the interlock device within the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. The shifter interlock cable can be adjusted or replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 789 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative battery cable from battery. 2. Place shifter in PARK position. 3. Remove tilt-wheel lever (pulls out). Lower Shroud Screws 4. Remove 2 lower shroud screws (size T25). Shroud Pivot Point 5. Upper and lower shrouds are snapped together at sides. Pivot points for lower and upper shrouds is at rear of shrouds. Lower shroud is hooked to pins on upper shroud. Tilt lower shroud down for removal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 790 Upper Shroud Screws 6. Remove 2 upper shroud screws (size T5) and remove upper shroud from steering column. 7. If removing key lock cylinder only, proceed to next step. If removing ignition switch, proceed to IGNITION SWITCH REMOVAL. 8. KEY LOCK CYLINDER REMOVAL: Ignition key must be in key cylinder for cylinder removal. a. Rotate and hold key in START position. Lock Cylinder Retainer Pin Access Hole b. Position a 1/16" pin punch into lock cylinder retainer pin access hole. c. Press in on pin punch to release lock cylinder retainer pin while releasing key to RUN position. d. Pull lock cylinder out for removal. 9. IGNITION SWITCH REMOVAL: Key lock cylinder removal is not necessary for ignition switch removal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 791 Installing Lock Cylinder To Column Removing/Installing Alarm Switch a. Remove alarm switch. Alarm switch is located at right/upper side of steering column. Press on retaining clip with a small screwdriver while rotating switch 1/4 turn for removal. b. Remove knee blocker below steering column. Refer to Knee Blocker in Instrument Panel Gauges And Warning Indicator. c. Note position of wiring harnesses and all tie wraps between ignition switch and 4 way connector at lower part of steering column. when installing ignition switch/wire harness assembly, the harnesses must be correctly routed with tie wraps in correct position to prevent damage to harness. d. If equipped with overdrive (OD) transmission, unclip OD wire harness at ignition switch. e. Cut necessary tie wraps. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 792 Ignition Switch Mounting Screws f. Remove 2 ignition switch mounting screws (size T4) and separate switch at steering column. Separating 48-Way Connectors At Lower Part Of Column g. Separate steering column 48-way electrical connectors by removing one fastener (bolt). The 48-way connector is located near lower part of steering column. This 48-way connector contains 48 different pin-outs including 3 different connectors: a 17-way for the multi-function switch; a 13-way for the multi-function switch; and an 18-way for the ignition switch. Separating 48-Way Connectors At Lower Part Of Column h. Separate 17-way multi-function switch connector from 18-way ignition switch connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 793 Steering Column 48-Way Connector (Male C0nnector To Column Shown) i. Separate 13-way multi-function switch connector from 18-way ignition switch connector. j. Separate multi-function switch wire harnesses from ignition switch wiring harness. k. Remove wiring harness and ignition switch as an assembly from steering column. INSTALLATION 1. KEY LOCK CYLINDER INSTALLATION: a. Place key into lock cylinder. b. Place key lock cylinder into steering column by aligning positioning tab on lock cylinder to positioning slot on steering column. Locking tab should also be aligned to locking tab slot. c. Press on lock cylinder until retaining pin engages. d. Rotate key to OFF position. e. Check for proper retention of lock cylinder by attempting to pull out on lock cylinder. 2. IGNITION SWITCH INSTALLATION: a. Position switch and wire harness assembly to steering column. b. Install switch screws and tighten to 1.4 N.m (12 in. lbs.) torque. c. Carefully route ignition switch wire harness down to bottom of steering column. d. If equipped with overdrive (OD) transmission, clip OD wire harness to ignition switch. e. Route alarm switch wire harness around ignition switch. f. Attach alarm switch to steering column by rotating and snapping into position). g. Attach 13-way multi-function switch connector to ignition switch 18-way connector. h. Attach 17-way multi-function switch connector to ignition switch 18-way connector. i. Attach both 48-way electrical connectors together (1 bolt). Tighten bolt to 7 N.m (62 in. lbs.) torque. j. Install new tie wraps in their previously noted positions. k. If equipped with a tilt steering wheel, operate tilt mechanism while observing wiring harnesses for binding. Correct binding if necessary. l. Operate shift lever while observing wiring harnesses for binding. Correct binding if necessary. 3. A 2-5/8" long plastic spacer is attached to inside of upper shroud. Before positioning shroud to column, verify spacer is tightened to upper shroud. 4. Position upper shroud to steering column. 5. Install 2 upper shroud screws. 6. Position rubber shields for shift lever and multi-function switch into upper shroud. 7. Position lower shroud hooks into pins on upper shroud. 8. Snap lower shroud to upper shroud. 9. Install 2 lower shroud screws. 10. Install tilt-wheel lever (snaps in). 11. Shifter should lock in PARK position when key is in LOCK position. Shifter should unlock when key rotated to ON position. 12. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 13. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify Steering wheel should unlock when key is rotated to ON position. 14. Connect negative battery cable to battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Switch, Park/Neutral ............................................................................................................................ ..................................................... 34 Nm (25 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 797 Solenoid Case Connector, Park/Neutral Position Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 798 Park/Neutral Position Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair > 32RH Transmission Neutral Safety Switch: Service and Repair 32RH Transmission REMOVAL 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. INSTALLATION Park/Neutral Position Switch 1. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 2. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 3. Test continuity of new switch with 12V test lamp. 4. Connect switch wires and lower vehicle. 5. Top off transmission fluid level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair > 32RH Transmission > Page 801 Neutral Safety Switch: Service and Repair 46RE Transmission REMOVAL 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. INSTALLATION Park/Neutral Position Switch 1. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 2. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 3. Test continuity of new switch with 12V test lamp. 4. Connect switch wires and lower vehicle. 5. Top off transmission fluid level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 812 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 818 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 822 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation TRANSMISSION SPEED SENSOR Transmission Output Speed Sensor The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The rear wheel speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. See: Sensors and Switches - Brakes and Traction Control/Wheel Speed Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation Power Window Switch: Description and Operation SYSTEM OPERATION The power windows are controlled by two-way momentary switches mounted in the mirror flag bezel on the trim panel of each front door. A second power window switch on the driver side bezel allows the driver to control the passenger side window. The power windows will only operate when the ignition switch is in the On position. The power window switches control the battery and ground feeds to the power window motors. The passenger side power window switch receives a ground feed through the driver side power window switch for operating the passenger side power window motor. The power window switches cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Page 833 Power Window Switch: Testing and Inspection Before you proceed with this diagnosis, confirm proper circuit breaker operation. See Circuit Breaker in the Diagnosis and Testing. 1. Remove the power window switch from the mirror flag bezel. See Power Window Switch Replacement. Carefully separate the wire harness connector from the switch body. Left Side Switch Continuity Power Window Switch Continuity - Passenger Side 2. Check the switch continuity in each position, as shown in the charts. If OK, see Power Window Motor in the Diagnosis and Testing. If not OK, replace the faulty power window switch unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Page 834 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the mirror flag bezel from the inside of the front door. Power Window Switch Remove/Install 3. From the back side of the mirror flag bezel, remove the screws that secure the power window and power lock switch and mounting plate unit to the mirror flag bezel. 4. Remove the power window and power lock switch and mounting plate unit from the mirror flag bezel. 5. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power window switch receptacle on the back of the switch mounting plate and pull the switch out of the receptacle. 6. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the switch mounting plate are fully engaged. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation Washer Fluid Level Switch: Description and Operation SYSTEM OPERATION Washer Fluid Level Sensor The washer fluid level sensor is mounted near the bottom of the rearward facing side of the washer reservoir. A barbed nipple on the sensor is press-fit into a rubber grommet seal installed in the mounting hole on the reservoir. When the fluid level in the washer reservoir falls below the travel limit of the float, the internal switch contacts of the sensor close. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Low Washer Fluid Warning Lamp. The washer fluid level sensor cannot be repaired. If faulty or damaged, the sensor unit must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Page 839 Washer Fluid Level Switch: Service and Repair REMOVAL 1. Remove the washer reservoir from the engine compartment. See Washer Reservoir Replacement. NOTE: The pivoting float of the washer fluid sensor must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and held in an upright position, the pivoting float will orient itself to the horizontal position when the sensor connector is pointed straight downwards. 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry the washer fluid level sensor out of the rubber grommet seal. Care must be taken not to damage the reservoir. 3. Remove the rubber grommet seal from the reservoir and discard. 4. Reverse the removal procedures to install. Always use a new rubber grommet seal on the reservoir. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation Windshield Washer Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch The windshield wiper and washer switches are integral to the multi-function switch assembly, which is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay interval. A paddle near the end of the switch stalk is rotated toward the instrument panel to activate the washer system. The multi-function switch also contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Horn contact and circuit. The information contained addresses only the multi-function switch windshield wiper and washer switches. For information relative to the other circuits and switches that are integral to the multi-function switch. However, the windshield wiper and washer switches cannot be repaired. If these switches or any other circuit of the multi-function switch is faulty or damaged, the entire multi-function switch assembly must be replaced. Refer to Turn Signal Switch and Hazard Warning Switch Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 843 Windshield Washer Switch: Testing and Inspection The wiper switch and washer switch are integral to the multi-function switch. See Wiper System and/or Washer System in the Diagnosis and Testing WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Unplug the steering column wire harness connector. Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the steering column half of the steering column wire harness connector terminals as shown in the Wiper Switch and Washer Switch Continuity chart. 3. If the wiper switch or the washer switch fails any of the continuity checks, repair the open circuit in the steering column wire harness or replace the faulty multi-function switch assembly as required. Refer to Lighting and Horns/Turn Signal/Turn Signal Switch and Hazard Warning Switch Replacement for the multi-function switch service procedures. If the switches are OK, repair the wiper system and/or washer system wire harness circuits as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 844 Windshield Washer Switch: Service and Repair REMOVAL AND INSTALLATION The wiper switch and washer switch are integral to the multi-function switch, which is installed on the left side of the steering column. If the wiper switch or the washer switch is faulty or damaged, the multi-function switch assembly must be replaced. Refer to Lighting and Horns/Turn Signal Switch and Hazard Warning Switch Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation Wiper Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch The windshield wiper and washer switches are integral to the multi-function switch assembly, which is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay interval. A paddle near the end of the switch stalk is rotated toward the instrument panel to activate the washer system. The multi-function switch also contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Horn contact and circuit. The information contained addresses only the multi-function switch windshield wiper and washer switches. For information relative to the other circuits and switches that are integral to the multi-function switch. However, the windshield wiper and washer switches cannot be repaired. If these switches or any other circuit of the multi-function switch is faulty or damaged, the entire multi-function switch assembly must be replaced. Refer to Turn Signal Switch and Hazard Warning Switch Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 848 Wiper Switch: Testing and Inspection The wiper switch and washer switch are integral to the multi-function switch. See Wiper System and/or Washer System in the Diagnosis and Testing WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Unplug the steering column wire harness connector. Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the steering column half of the steering column wire harness connector terminals as shown in the Wiper Switch and Washer Switch Continuity chart. 3. If the wiper switch or the washer switch fails any of the continuity checks, repair the open circuit in the steering column wire harness or replace the faulty multi-function switch assembly as required. Refer to Lighting and Horns/Turn Signal/Turn Signal Switch and Hazard Warning Switch Replacement for the multi-function switch service procedures. If the switches are OK, repair the wiper system and/or washer system wire harness circuits as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 849 Wiper Switch: Service and Repair REMOVAL AND INSTALLATION The wiper switch and washer switch are integral to the multi-function switch, which is installed on the left side of the steering column. If the wiper switch or the washer switch is faulty or damaged, the multi-function switch assembly must be replaced. Refer to Lighting and Horns/Turn Signal Switch and Hazard Warning Switch Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 859 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 860 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 861 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 867 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 868 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 869 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised Alignment: All Technical Service Bulletins Steering Wander - Diagnosis and Correction Revised NUMBER: 19-07-00 GROUP: Steering DATE: September 22, 2000 SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering wander. MODELS: 1998-2001 (AB) Ram Van/Wagon SYMPTOM/CONDITION: Steering Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering wander can be created by a number of different conditions including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying extra added weight (e.g. tool boxes). ^ Steering and/or suspension components that are worn or damaged. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: UNDER CERTAIN ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. DIAGNOSIS: 1. Verify that the vehicle is not equipped with non-factory installed options or equipment that may cause the vehicle to wander such as heavy toolboxes or hardware that may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended may cause the vehicle to wander and should be replaced before continuing with the diagnosis. 3. Inflate all tires to the pressure specified in the Tire Inflation Pressure sheet (located in the glove box). NOTE: TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS BUT, ONLY IF THE VEHICLE IS AT CURB OR LIGHT LOAD CONDITIONS. 4. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without cross wind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Proceed to the next step if the vehicle exhibits a steering wander condition. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-3 OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, ETC.). 5. Raise the vehicle on an appropriate lift. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised > Page 874 6. Secure a dial indicator to the lower control arm. Position the dial indicator so that the tip of the indicator contacts the inside face of the rotor (Figure 1). 7. Place your hands at the top and bottom of the tire/wheel assembly and push the tire/wheel assembly inboard (Figure 2). Zero the dial indicator. With your hands at the top and bottom of the tire/wheel assembly, pull the tire/wheel assembly outboard (Figure 3). Record the dial indicator reading. Perform this procedure on both front wheel bearings and proceed to the next step if the wheel bearing endplay exceeds 0.025 - 0.076 mm (0.001 - 0.003 in.). Proceed to Step 9 if wheel-bearing endplay on both front wheel bearings are within specifications. NOTE: WHEEL BEARING INSPECTION AND ADJUSTMENT IS ONLY REQUIRED ON WHEEL BEARINGS EXCEEDING 0.025 - 0.076 MM (0.001 - 0.003 IN.) ENDPLAY. 8. Remove the wheel bearing protective end cap, cotter pin, nut lock, nut, and washer from the spindle. Inspect the wheel bearings. If it is determined that wheel bearing replacement is necessary, refer to the appropriate Ram Van/Wagon Service Manual, Group 02, Wheel Bearings, for removal and installation information. Reinstall the wheel bearings, washer, and adjustment nut if the wheel bearings pass the inspection. 9. Using a torque wrench, tighten the wheel bearing adjustment nut to 54 N.m (40 ft. lbs.) while rotating the tire/wheel assembly. Stop the wheel from rotating and loosen the nut. Using the procedure identified in Steps 6 and 7 to measure endplay, adjust the front wheel bearing endplay until 0.025 - 0.076 mm (0.001 - 0.003 in.) endplay has been achieved. Install the nut lock and a new cotter pin. 10. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual. Any worn steering and/or suspension component must be replaced prior to performing an alignment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised > Page 875 11. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the chart for proper alignment specifications. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised Alignment: All Technical Service Bulletins Steering Wander - Diagnosis and Correction Revised NUMBER: 19-07-00 GROUP: Steering DATE: September 22, 2000 SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering wander. MODELS: 1998-2001 (AB) Ram Van/Wagon SYMPTOM/CONDITION: Steering Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering wander can be created by a number of different conditions including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying extra added weight (e.g. tool boxes). ^ Steering and/or suspension components that are worn or damaged. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: UNDER CERTAIN ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. DIAGNOSIS: 1. Verify that the vehicle is not equipped with non-factory installed options or equipment that may cause the vehicle to wander such as heavy toolboxes or hardware that may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended may cause the vehicle to wander and should be replaced before continuing with the diagnosis. 3. Inflate all tires to the pressure specified in the Tire Inflation Pressure sheet (located in the glove box). NOTE: TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS BUT, ONLY IF THE VEHICLE IS AT CURB OR LIGHT LOAD CONDITIONS. 4. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without cross wind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Proceed to the next step if the vehicle exhibits a steering wander condition. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-3 OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, ETC.). 5. Raise the vehicle on an appropriate lift. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised > Page 881 6. Secure a dial indicator to the lower control arm. Position the dial indicator so that the tip of the indicator contacts the inside face of the rotor (Figure 1). 7. Place your hands at the top and bottom of the tire/wheel assembly and push the tire/wheel assembly inboard (Figure 2). Zero the dial indicator. With your hands at the top and bottom of the tire/wheel assembly, pull the tire/wheel assembly outboard (Figure 3). Record the dial indicator reading. Perform this procedure on both front wheel bearings and proceed to the next step if the wheel bearing endplay exceeds 0.025 - 0.076 mm (0.001 - 0.003 in.). Proceed to Step 9 if wheel-bearing endplay on both front wheel bearings are within specifications. NOTE: WHEEL BEARING INSPECTION AND ADJUSTMENT IS ONLY REQUIRED ON WHEEL BEARINGS EXCEEDING 0.025 - 0.076 MM (0.001 - 0.003 IN.) ENDPLAY. 8. Remove the wheel bearing protective end cap, cotter pin, nut lock, nut, and washer from the spindle. Inspect the wheel bearings. If it is determined that wheel bearing replacement is necessary, refer to the appropriate Ram Van/Wagon Service Manual, Group 02, Wheel Bearings, for removal and installation information. Reinstall the wheel bearings, washer, and adjustment nut if the wheel bearings pass the inspection. 9. Using a torque wrench, tighten the wheel bearing adjustment nut to 54 N.m (40 ft. lbs.) while rotating the tire/wheel assembly. Stop the wheel from rotating and loosen the nut. Using the procedure identified in Steps 6 and 7 to measure endplay, adjust the front wheel bearing endplay until 0.025 - 0.076 mm (0.001 - 0.003 in.) endplay has been achieved. Install the nut lock and a new cotter pin. 10. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual. Any worn steering and/or suspension component must be replaced prior to performing an alignment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised > Page 882 11. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the chart for proper alignment specifications. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 883 Alignment: By Symptom Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 884 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 885 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 886 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 887 ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 888 THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 889 CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 890 This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 891 TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 892 The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 893 NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 894 Alignment: Specifications CASTER: Preferred .............................................................................................................................................. ...................................................................... +2.5° Range ................................................................. ..................................................................................................................................................... ± 1.50° Maximum Right/Left Difference .................................................................................................. ............................................................................. 1.25° CAMBER: Preferred .............................................................................................................................................. ........................................................................... 0° Range ................................................................. ....................................................................................................................................................... ± 0.6° Maximum Right/Left Difference .................................................................................................... ................................................................................ 0° TOTAL TOE-IN: Preferred .............................................................................................................................................. ........................................................................... 0° Range ................................................................. ..................................................................................................................................................... ± 0.25° Maximum Right/Left Difference .................................................................................................. ............................................................................. 0.05° THRUST ANGLE Preferred .............................................................................................................................................. ........................................................................... 0° Range ................................................................. ....................................................................................................................................................... ± 0.4° Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 895 Alignment: Description and Operation GENERAL INFORMATION Wheel Alignment Measurements Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. Caster - is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides negative caster. Tilting the top of the knuckle rearward provides positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns. Camber - is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire. Toe - is the difference between the leading inside edges and trailing inside edges of the front tires. Uneven wheel toe position cause's unstable steering, uneven tire near and steering wheel off-center. The wheel toe position is the final front wheel alignment adjustment. Thrust Angle - is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 896 Alignment: Testing and Inspection PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear or adjustment. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 897 Alignment: Service and Repair GENERAL INFORMATION The front wheel alignment angles should be set to preferred specifications. This will prevent abnormal tire tread wear. Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down several times. Always release the bumper in the down position. CAMBER AND CASTER Camber and caster angle adjustments involve repositioning the upper suspension arm pivot bar. Alignment adjustments are accomplished by changing the position of the pivot bar. Adjuster Tool 8199, or equivalent is used to adjust the camber and caster angles. Tools Attached To Frame 1. Clamp the tool on the upper suspension arm frame bracket. Use the two clamp bolts to attach the tool to the bracket. 2. With the adjustment tools installed, loosen both upper suspension arm bolts completely. 3. Tighten or loosen the tool adjustment bolts to move the upper suspension arm inward or outward to obtain the proper camber and caster angles. Caster: Move the rear position of the pivot bar in or out. This will change the caster angle significantly and camber angle only slightly. To retain the camber while adjusting caster, move the rear pivot bar in or out. Move the forward pivot very slightly in the opposite direction. NOTE: For example, to increase a positive caster angle move the rear position of the pivot bar inward. Move the front of pivot bar outward until the original camber angle is obtained. Camber: Move the forward position of the pivot bar in or out. This will change the camber angle significantly and caster angle only slightly. The camber angle should be adjusted to the service specifications. Tighten the pivot bar bolts to 298 Nm (220 ft. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 898 TOE POSITION The wheel toe position is the final adjustment procedure. 1. Secure the steering wheel with the front wheels in the straight ahead position. For power steering vehicles, start the engine before straightening the wheels. 2. Loosen the tie rod adjustment sleeve clamp bolts. 3. Adjust the wheel toe position by rotating the tie rod adjustment sleeve. 4. Position the adjustment sleeve clamps so the ends are not located at the sleeve slot. Tighten the tie rod sleeve clamps to: - Standard Duty: 23 Nm (17 ft. lbs.) - Heavy Duty: 35 Nm (26 ft. lbs.) Ensure the clamp bolts are located at the underside of the sleeve. 5. Verify camber, caster and toe position. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 899 Adjuster, Caster & Camber 8119 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage NO: 14-03-98 GROUP: Fuel DATE: May 1, 1998 SUBJECT: Fuel Pressure Gauge Adapter Usage MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) DISCUSSION: Currently, four different fuel pressure adapters are required, depending on application, to attach a fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications Fuel Pressure: Pressure, Vacuum and Temperature Specifications Fuel Pressure Engine at curb idle ............................................................................................................................... ........................................ 339 ± 34 kPa (49.2 ± 5 psi) Pressure Leakdown (fuel pump not engaged) ................................................................................................................. Not fall below 30 psi for 5 minutes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 907 Fuel Pressure: Capacity Specifications NOTE: Before performing this test, verify fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. - Refer to the Fuel Pressure Release Procedure. 2. Disconnect the fuel supply line at fuel rail. - Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. - Insert other end of Adaptor Tool hose into a graduated container. 4. Remove the fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. - Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. - Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test Fig 9 Connecting Adaptor Tool -- Typical Fig. 8 Installing Adapter Tool And Pressure Gauge NOTE: Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: Fuel pressure bleeding past a fuel injector(s). - Fuel pressure bleeding past the check valve in the fuel pump module. 1. Disconnect the fuel inlet line at fuel rail. - On some engines, air cleaner housing removal may be necessary before fuel line disconnection. 2. Connect the appropriate Fuel Line Pressure Test Adapter Tool (number 6539, 6631, 6541 or 6923) between the disconnected fuel line and fuel rail (Fig. 9) or (Fig. 10). 3. Connect the 0-414 kPa (0-60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. - The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 4. Start engine and bring to normal operating temperature. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 910 5. Observe test gauge. Normal operating pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). 6. Shut engine off. 7. Pressure should not fall below 30 psi for five minutes. 8. If pressure falls below 30 psi, it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 9. Again, start engine and bring to normal operating temperature. 10. Shut engine off. 11. Testing for fuel injector or fuel rail leakage: - Clamp off the rubber hose portion of Adaptor Tool between the fuel rail and the test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a fuel injector or the fuel rail is leaking. 12. Testing for fuel pump check valve, filter/regulator check valve or fuel tube/line leakage: - Clamp off the rubber hose portion of Adaptor Tool between the vehicle fuel line and test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a leak may be found at a fuel tube/line. - If no leaks are found at fuel tubes or lines, one of the check valves in either the electric fuel pump or filter/ regulator may be leaking. NOTE: A quick loss of pressure usually indicates a defective check valve in the filter/regulator. A slow loss of pressure usually indicates a defective check valve in the electric fuel pump. The electric fuel pump is not serviced separately -- Replace the fuel pump module assembly. The filter/ regulator may be replaced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/installation for additional information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 911 Fuel Pressure: Testing and Inspection Fuel Pressure Test Fuel Pressure Test Gauge NOTE: Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test, fuel pump amperage test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow hack into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. WARNING: The fuel system is under constant fuel pressure even with the engine off. Before disconnecting fuel line at fuel rail, this pressure must be released. Refer to the fuel system pressure release procedure. NOTE: To perform this test you will need to remove the engine cover. 1. Remove the protective cap at the fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port pressure fitting on the fuel rail. 2. Start and warm the engine and note pressure gauge reading. Fuel pressure should be 3.39 kPa +/- 34 kPa (49.2 psi +/- 5 psi) at idle. 3. If engine runs but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, replace fuel pump module assembly. Refer to Fuel Pump Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel filter/fuel pressure regulator. Certain filter/regulators may be serviced separately and some require the replacement of the fuel pump module assembly Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 912 Fuel Pressure: Testing and Inspection Fuel Pump Amperage Test This amperage (current draw) test is to be done in conjunction with the Fuel Pump Pressure Test, Fuel Pump Capacity Test and Fuel Pressure Leak Down Test. Before performing the amperage test, be sure the temperature of the fuel tank is above 50° F (10° C). The DRB Scan Tool along with the DRB Low Current Shunt (LCS) adapter and its test leads will be used to check fuel pump amperage specifications. Low Current Shunt Adapter 1. Obtain LCS adapter. 2. Plug cable from LCS adapter into DRB scan tool at SET 1 receptacle. 3. Plug DRB into vehicle 16-way connector (data link connector). 4. Connect (-) and (+) test cable leads into LCS adapter receptacles. Use 10 amp (10A +) receptacle and common (-) receptacles. 5. Gain access to MAIN MENU on DRB screen. 6. Press DVOM button on DRB. 7. Using left/right arrow keys, highlight CHANNEL 1 function on DRB screen. 8. Press ENTER three times. 9. Using up/down arrow keys, highlight RANGE on DRB screen (screen will default to 2 amp scale). 10. Press ENTER to change 2 amp scale to 10 amp scale. This step must be done to prevent damage to DRB scan tool or LCS adapter (blown fuse). 11. Remove cover from Power Distribution Center (PDC). 12. Remove fuel pump relay from PDC. Refer to label on PDC cover for relay location. WARNING: BEFORE PROCEEDING TO NEXT STEP, NOTE THE FUEL PUMP WILL BE ACTIVATED AND SYSTEM PRESSURE WILL BE PRESENT. THIS WILL OCCUR AFTER CONNECTING TEST LEADS FROM LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES. THE FUEL PUMP WILL OPERATE EVEN WITH IGNITION KEY IN OFF POSITION. BEFORE ATTACHING TEST LEADS, BE SURE ALL FUEL LINES AND FUEL SYSTEM COMPONENTS ARE CONNECTED. CAUTION: To prevent possible damage to the vehicle electrical system and LCS adapter, the test leads must be connected into relay cavities exactly as shown in following steps. Depending upon vehicle model, year or engine configuration, three different types of relays may be used: Type-1, type-2 and type-3. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 913 Starter Relay 13 If equipped with type-1 relay, attach test leads from LCS adapter into PDC relay cavities number 30 and 87. For location of these cavities, refer to numbers stamped to bottom of relay. Type-2 Relay 14. If equipped with type-2 relay, attach test leads from LCS adapter into PDC relay cavities number 30 and 87. For location of these cavities, refer to numbers stamped to bottom of relay. Type-3 Relay 15. If equipped with type-3 relay, attach test leads from LCS adapter into PDC relay cavities number 3 and 5. For location of these cavities, refer to numbers stamped to bottom of relay. 16. When LCS adapter test leads are attached into relay cavities, fuel pump will be activated. Determine fuel pump amperage on DRB screen. Amperage should be below 10.0 amps. If amperage is below 10.0 amps, and specifications for the Fuel Pump Pressure, Fuel Pump Capacity and Fuel Pressure Leak Down tests were met, the fuel pump module is OK. 17. If amperage is more than 10.0 amps, replace fuel pump module assembly The electric fuel pump is not serviced separately. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 914 18. Disconnect test leads from relay cavities immediately after testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 915 Fuel Pressure: Testing and Inspection Fuel Pump Capacity Test NOTE: Before performing this test, verify fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. - Refer to the Fuel Pressure Release Procedure. 2. Disconnect the fuel supply line at fuel rail. - Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. - Insert other end of Adaptor Tool hose into a graduated container. 4. Remove the fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. - Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. - Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions Air/Fuel Mixture: Technical Service Bulletins Fuel System/Engine Controls - Manual Revisions NUMBER: 26-02-99A GROUP: Miscellaneous DATE: February, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revision to the Diagnostic Trouble Codes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 920 45 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 921 46 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 922 47 Revision to the Throttle Position Sensor connector pin outs Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 923 152 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 924 156 Revision to the Fuel System Rich test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 925 316 Revisions to the Throttle Position sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 926 620 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 927 622 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ......................................................... 500 to 900 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 931 Idle Speed: Testing and Inspection The following test procedure has been developed to check throttle body calibrations for correct idle conditions. The procedure should be used to diagnose the throttle body for conditions that may cause idle problems. This procedure should be used only after normal diagnostic procedures have failed to produce results that indicate a throttle body related problem. Be sure to check for proper operation of the idle air control motor before performing this test. Fig. 73 Fixed Orifice Tool A special fixed orifice tool (number 6714) must be used for the following test. 1. Start the engine and bring to operating temperature. Be sure all accessories are off before performing this test. 2. Shut off the engine and remove the air cleaner element housing. Fig. 74 Install Orifice Tool 3. Disconnect the vacuum line at the PCV valve. 4. Install the 0.185 inch orifice tool (number 6714) into the disconnected vacuum line in place of the PCV valve. Fig. 75 Idle Purge Line Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 932 5. Disconnect the idle purge vacuum line from fitting at throttle body This vacuum line is located on the front of throttle body next to the MAP sensor. Cap the fitting at throttle body after vacuum line has been removed. 6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under the instrument panel to the left of the steering column. 7. Start the engine. 8. Using the DRB scan tool, scroll through the menus as follows: select-System, select-Engine, select-Fuel and Ignition, select-Actuator Tests, select Engine rpm and select-Minimum Air Flow. 9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm. The idle rpm should be between 500 and 900 rpm. If the idle speed is outside of these specifications, replace the throttle body. 10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV valve. 13. Install air cleaner element housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair Fig 52 Air Cleaner Components -- Typical REMOVAL 1. From engine compartment, remove plastic air intake tube at front of air cleaner housing. Tube snaps onto air cleaner housing. 2. Remove engine cover. 3. Pull crankcase breather/filter (straight up) from engine valve cover. 4. Remove wing nut and remove air cleaner assembly from throttle body. INSTALLATION 1. Position air cleaner housing to throttle body. 2. If housing-to-throttle body mounting stud is being installed, tighten to 10 N.m (90 in. lbs.) torque. 3. Tighten wingnut to 1.5 N.m (15 in. lbs.) torque. 4. Push crankcase breather/filter into valve cover. 5. Install plastic air intake tube to housing. 6. Install engine cover. AIR CLEANER ELEMENT Housing removal is not necessary for element (filter) replacement. REMOVAL 1. Remove engine cover. 2. Remove wingnut and remove cover from housing. 3. Remove air cleaner element from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Install housing cover to housing. 3. Install wingnut. 4. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair NOTE: Use following procedure if fuel rail is or is not equipped with fuel pressure test port. 1. Remove fuel fill cap. 2. The fuel filler tube contains a spring-loaded flap (door) located below fuel fill cap. The flap is used as a secondary way of sealing fuel tank if fuel fill cap has not been properly tightened. It is part of EVAP monitor system when vehicle is equipped with a Leak Detection Pump (LDP). The vehicle may be equipped with flap installed into fuel filler tube even though vehicle is not equipped with LDP and EVAP monitor system. Place a nonmetallic object into fuel fill tube and press on flap to relieve any tank pressure. 3. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 7. Unplug connector from any injector. 8. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 9. Connect other end of jumper wire to positive side of battery. 10. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 11. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 12. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 13. Disconnect quick-connect fitting at fuel rail. 14. Return fuel pump relay to PDC. 15. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 955 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 956 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 957 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 958 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 959 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 960 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 966 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 967 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 968 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 969 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 970 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 971 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 972 Ignition Cable: Specifications MINIMUM = MAXIMUM 250 Ohms Per Inch = 1000 Ohms Per Inch 3000 Ohms Per Foot = 12,000 Ohms Per Foot Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 973 Ignition Cable: Description and Operation SYSTEM OPERATION Spark plug cables are sometimes referred to as secondary ignition wires. These cables transfer electrical current from the ignition coil(8) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 974 Ignition Cable: Testing and Inspection Heat Shields Check the spark plug cable connections for good contact at the coil(s), distributor cap towers, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, distributor and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean high voltage ignition cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Spark plug cable heat shields are pressed into the cylinder head to surround each spark plug cable boot and spark plug . These shields protect the spark plug boots from damage (due to intense engine heat generated by the exhaust manifolds) and should not be removed. After the spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat shield. Testing When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment manufacturer. If an oscilloscope is not available, spark plug cables may be tested as follows: CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. With the engine running, remove spark plug cable from spark plug (one at a time) and hold next to a good engine ground. If the cable and spark plug are in good condition, the engine rpm should drop and the engine will run poorly If engine rpm does not drop, the cable and/or spark plug may not be operating properly and should be replaced. Also check engine cylinder compression. With the engine not running, connect one end of a test probe to a good ground. Start the engine and run the other end of the test probe along the entire length of all spark plug cables. If cables are cracked or punctured, there will be a noticeable spark jump from the damaged area to the test probe. The cable running from the ignition coil to the distributor cap can be checked in the same manner. Cracked, damaged or faulty cables should be replaced with resistance type cable. This can be identified by the words ELECTRONIC SUPPRESSION printed on the cable jacket. Use an ohmmeter to test for open circuits, excessive resistance or loose terminals. If equipped, remove the distributor cap from the distributor. Do not remove cables from cap. Remove cable from spark plug. Connect ohmmeter to spark plug terminal end of cable and to corresponding electrode in distributor cap. Resistance should be 250 to 1000 Ohms per inch of cable. If not, remove cable from distributor cap tower and connect ohmmeter to the terminal ends of cable. If resistance is not within specifications as found in the SPARK PLUG CABLE RESISTANCE chart, replace the cable. Test all spark plug cables in this manner. Spark Plug Cable Resistance MINIMUM = MAXIMUM 250 Ohms Per Inch = 1000 Ohms Per Inch 3000 Ohms Per Foot = 12,000 Ohms Per Foot To test ignition coil-to-distributor cap cab]e, do not remove the cable from the cap. Connect ohmmeter to rotor button (center contact) of distributor cap and terminal at ignition coil end of cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, remove the cable from the distributor cap. Connect the ohmmeter to the terminal ends of the cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, replace the cable. Inspect the ignition coil tower for cracks, burns or corrosion. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 975 Ignition Cable: Service and Repair REMOVAL AND INSTALLATION Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Engine Firing Order Install cables into the proper engine cylinder firing order. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Cap Inspection-External-Typical Cap Inspection-Internal-Typical Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. The machined surface of a terminal end (faces toward rotor) will indicate some evidence of erosion from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Rotor Inspection-Typical Visually inspect the rotor for cracks, evidence of corrosion or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... ..................................................... 0.89 mm (0.035 in) Torque ............................................................ ............................................................................................................................................... 41 Nm (30 ft lb) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 986 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ..................................................................... RC12YC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 987 Spark Plug: Description and Operation SYSTEM OPERATION All engines use resistor type spark plugs. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Spark plugs that have low milage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 988 Spark Plug: Testing and Inspection Normal Operating Spark Plug Cable Resistance The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Cold Fouling/Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operating times (short trips). Wet Fouling Or Gas Fouling A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Oil Or Ash Encrusted Oil Or Ash Encrusted If one or more spark plugs are oil or oil ash encrusted, evaluate engine condition for the cause of oil entry into that particular combustion chamber. Electrode Gap Bridging Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 989 Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Scavenger Deposits Scavenger Deposit Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy, but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Chipped Electrode Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Preignition Damage Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 990 Preignition Damage Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Spark Plug Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 991 Spark Plug: Service and Repair Heat Shields Spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. PLUG REMOVAL 1. Remove engine cover. 2. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result, 3. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber. 4. Remove the spark plug using a quality socket with a rubber or foam insert. 5. Inspect the spark plug condition. Plug Cleaning The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator arid will cause plug misfire. Plug Gap Adjustment Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. Spark Plug Gap V-8 Engines: 1.01 mm (.040 in). PLUG INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. when replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 N.m (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi) from cylinder to cylinder. If cylinder(s) have abnormally low compression pressures, repeat procedure. - If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a problem in the cylinder. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should NOT be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 995 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. Minimum cylinder compression pressure is 689 kPa (100 psi). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Belt Routing-All Engines Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1002 Drive Belt: Description and Operation ACCESSORY DRIVE BELT/TENSION The accessory drive components are operated by a single, crankshaft driven, serpentine drive belt. An automatic belt tensioner is used to maintain correct belt tension at all times. Correct accessory drive belt tension is required to be sure of optimum performance of belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate and greatly reduced belt life. It is not necessary to adjust belt tension on any engine. All engines are equipped with an automatic belt tensioner. The tensioner maintains correct belt tension at all times. Due to use of this belt tensioner, do not attempt to use a belt tension gauge on any engine. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1003 Drive Belt: Testing and Inspection VISUAL DIAGNOSIS Belt Ware Patterns When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to the Accessory Drive Belt Diagnosis charts for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1004 ACCESSORY DRIVE BELT DIAGNOSIS CHART Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1005 Drive Belt: Service and Repair ACCESSORY DRIVE BELT The accessory drive components are operated by a single, crankshaft driven, serpentine drive belt. An automatic belt tensioner is used to maintain correct belt tension at all times. CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner. REMOVAL Belt Tensioner-Typical 1. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 2. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from idler pulley first. 4. Remove belt from vehicle. INSTALLATION Belt Routing-All Engines CAUTION: When installing "serpentine" accessory drive belt, belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. The correct belt with correct length must be used. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1006 The following belt routing schematics are published from the latest information available at the time of publication. If anything differs between these schematics and the Belt Routing Label, use the schematics on Belt Routing Label. This label is located in the engine compartment. 1. Position drive belt over all pulleys except idler pulley. This pulley is located between generator and A/C compressor. 2. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 3. Rotate socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly seated on all pulleys. Tensioner Indexing Marks 4. Check belt indexing marks. 5. The tensioner is equipped with an indexing arrow on back of tensioner and an indexing mark on tensioner housing. If a new belt is being installed, arrow must be within approximately 3 mm (1/8 in.) of indexing mark (Point B). Belt is considered new if it has been used 15 minutes or less. If this specification cannot be met, check for: ^ The wrong belt being installed (incorrect length/ width) ^ Worn bearings on an engine accessory (A/C compressor, power steering pump, water pump, idler pulley or generator) ^ A pulley on an engine accessory being loose ^ Misalignment of an engine accessory ^ Belt incorrectly routed. A used belt should be replaced if tensioner indexing arrow has moved beyond point A. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair Fig 52 Air Cleaner Components -- Typical REMOVAL 1. From engine compartment, remove plastic air intake tube at front of air cleaner housing. Tube snaps onto air cleaner housing. 2. Remove engine cover. 3. Pull crankcase breather/filter (straight up) from engine valve cover. 4. Remove wing nut and remove air cleaner assembly from throttle body. INSTALLATION 1. Position air cleaner housing to throttle body. 2. If housing-to-throttle body mounting stud is being installed, tighten to 10 N.m (90 in. lbs.) torque. 3. Tighten wingnut to 1.5 N.m (15 in. lbs.) torque. 4. Push crankcase breather/filter into valve cover. 5. Install plastic air intake tube to housing. 6. Install engine cover. AIR CLEANER ELEMENT Housing removal is not necessary for element (filter) replacement. REMOVAL 1. Remove engine cover. 2. Remove wingnut and remove cover from housing. 3. Remove air cleaner element from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Install housing cover to housing. 3. Install wingnut. 4. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Description and Operation Crankcase Filter: Description and Operation Fig 9 Crankcase Breather Filter CRANKCASE BREATHER/FILTER The crankcase breather/filter (Fig. 9) is located on the cylinder head (valve) cover. The filter may be cleaned by washing it thoroughly in kerosene or an equivalent. Filter must be thoroughly drained. More frequent service may be necessary for vehicles operated extensively on short run, stop and go, extended engine idle service or extreme dust conditions. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair NOTE: Use following procedure if fuel rail is or is not equipped with fuel pressure test port. 1. Remove fuel fill cap. 2. The fuel filler tube contains a spring-loaded flap (door) located below fuel fill cap. The flap is used as a secondary way of sealing fuel tank if fuel fill cap has not been properly tightened. It is part of EVAP monitor system when vehicle is equipped with a Leak Detection Pump (LDP). The vehicle may be equipped with flap installed into fuel filler tube even though vehicle is not equipped with LDP and EVAP monitor system. Place a nonmetallic object into fuel fill tube and press on flap to relieve any tank pressure. 3. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 7. Unplug connector from any injector. 8. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 9. Connect other end of jumper wire to positive side of battery. 10. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 11. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 12. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 13. Disconnect quick-connect fitting at fuel rail. 14. Return fuel pump relay to PDC. 15. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter Connector 50 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1021 Oil Filter: Description and Operation FILTER SPECIFICATION All Dodge Ram engines are equipped with a high quality full-flow, disposable type oil filter. Chrysler Corporation recommends a Mopar or equivalent oil filter be used. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1022 Oil Filter: Service and Repair OIL FILTER REMOVAL 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter. Oil Filter Removal-Typical 3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss. 4. When filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove filter from vehicle. Oil Filter Sealing Surface-Typical 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. OIL FILTER INSTALLATION 1. Lightly lubricate oil filter gasket with engine oil or chassis grease. 2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, hand tighten filter one full turn, do not over tighten. 3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Description and Operation Refrigerant Filter: Description and Operation SYSTEM OPERATION A single filter-drier unit is used for both the front-only A/C system, and for the combined front and rear A/C system. The filter-drier is mounted on the right side of the engine compartment in front of the heater-A/C housing. It is located in the liquid line between the condenser outlet and the evaporator inlet. Refrigerant enters the filter-drier as a high-pressure, high-temperature liquid. The filter-drier performs a filtering action to prevent foreign material in the refrigerant from contaminating the expansion valve. A desiccant bag is mounted inside the filter-drier canister to absorb any moisture which may have entered and become trapped within the refrigerant system. In addition, during periods of high demand air conditioner operation, the filter-drier acts as a reservoir to store surplus liquid refrigerant. The filter-drier cannot be repaired. If the filter-drier is faulty or damaged, if the refrigerant system has been contaminated, or if the system has been left open to the atmosphere for an indeterminable period, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Description and Operation > Page 1026 Refrigerant Filter: Service and Repair WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Filter-Drier Remove/Install 3. Remove the screw that secures the filter-drier to its mounting bracket. 4. Remove the screw that secures the liquid line block fitting to the filter-drier inlet. Separate the liquid line block fitting from the filter-drier inlet. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the screw that secures the filter-drier outlet to the suction line jumper block fitting. Separate the filter-drier outlet from the suction line jumper block fitting. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Remove the filter-drier from the engine compartment. INSTALLATION 1. Remove the tape or plugs from the suction line jumper block fitting and the filter-drier outlet. Position the filter-drier outlet to the suction line jumper block fitting and secure the connection with a screw. Tighten the mounting screw to 13.5 N.m (120 in. lbs.). 2. Remove the tape or plugs from the liquid line block fitting and the filter-drier inlet. Position the liquid line block fitting to the filter-drier inlet and secure the connection with a screw. Tighten the mounting screw to 13.5 N.m (120 in. lbs.). 3. Reinstall the screw that secures the filter-drier to its mounting bracket. Tighten the mounting screw 8.5N.m (75 in. lbs.). 4. Connect the battery negative cable. 5. Evacuate the refrigerant system. 6. Charge the refrigerant system. NOTE: If the filter-drier is replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Description and Operation Coolant Line/Hose: Description and Operation Radiator Hoses-Typical Rubber hoses route coolant to and from the radiator, intake manifold and heater core. Radiator lower hoses are spring-reinforced to prevent collapse from water pump suction at moderate and high engine speeds. Inspect the hoses at regular intervals. Replace hoses that are cracked, feel brittle when squeezed or swell excessively when the system is pressurized. The use of molded replacement hoses is recommended. When performing a hose inspection, inspect the radiator lower hose for proper position and condition of the spring. Hose Clamp Tool-Typical WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Description and Operation > Page 1031 Clamp Number/Letter Location CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. For all vehicles: In areas where specific routing and clamps are not provided, be sure that hoses are positioned with sufficient clearance. Check clearance from exhaust manifolds and pipe, fan blades, drive belts and sway bars. Improperly positioned hoses can be damaged, resulting in coolant loss and engine overheating. Ordinary worm gear type hose clamps (when equipped) can be removed with a straight screwdriver or a hex socket. To prevent damage to hoses or clamps, the hose clamps should be tightened to 4 Nm (34 inch lbs.) torque. Do not over tighten hose clamps. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Rear Heater-A/C Unit Plumbing Heater Hose: Service and Repair Rear Heater-A/C Unit Plumbing The rear heater-A/C unit plumbing is used only on models with the optional rear heater-A/C unit. while the formed metal rear heater-A/C unit suction line, liquid line, and heater lines are available for separate service replacement, the rear heater-A/C unit must be removed from the vehicle in order to service them. The molded and straight heater hoses used on the rear heater-A/C unit can be serviced in the vehicle. Any kinks or sharp bends in the rear heater-A/C unit plumbing will reduce the capacity of the entire heating and air conditioning system. Kinks and sharp bends reduce the system flow. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. High temperature coolant is present in the heater plumbing when the engine is operating. Extreme care must be exercised to make sure that each of the plumbing connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Remove the rear heater-A/C unit from the vehicle. 2. Disconnect the rear heater-A/C unit liquid and suction lines from the expansion valve. See Expansion Valve - Rear replacement procedures. 3. Disconnect the rear heater-A/C unit heater hoses from the heater inlet and outlet lines. Rear Heater-A/c Plumbing Remove/Install 4. Disengage the seal from the plumbing plate, which is secured to the forward outboard corner of the rear heater-A/C unit lower housing. Push the bottom of the seal out through the top of the plumbing plate from underneath. 5. Remove the plumbing lines and seal as an assembly from the rear heater-A/C unit. 6. If the suction line is being serviced, remove the tie-wraps that secure each end of the insulator to the line, then slide the insulator off. 7. Push the line through the hole from the top of the seal, twisting and turning the line as needed, while pulling it from the bottom of the seal. INSTALLATION 1. Push the line through the hole from the bottom of the seal, twisting and turning the line as needed, while pulling it from the top of the seal. 2. If the suction line is being serviced, slide the insulator onto the line, then secure each end of the insulator to the line with a tie-wrap. 3. Position the plumbing lines and seal as an assembly to the rear heater-A/C unit. 4. Reinstall the seal to the plumbing plate. Push the seal into the plumbing plate from the top until it is fully seated. 5. Connect the rear heater-A/C unit heater hoses to the heater inlet and outlet lines. 6. Connect the rear heater-A/C unit liquid and suction lines to the expansion valve. 7. Reinstall the rear heater-A/C unit in the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Rear Heater-A/C Unit Plumbing > Page 1036 Heater Hose: Service and Repair Underbody Plumbing The underbody plumbing lines are used only on models with the optional rear heater-A/C unit. While the underbody suction line, liquid line, and combination heater line are available for separate service replacement, all lines must be removed from the vehicle as a unit for service. Any kinks or sharp bends in the underbody plumbing will reduce the capacity of the entire heating and air conditioning system. Kinks and sharp bends reduce the system flow. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. High temperature coolant is present in the heater plumbing when the engine is operating. Extreme care must be exercised to make sure that each of the plumbing connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 4. From the engine compaftment, disconnect the underbody liquid line at the liquid line extension and the underbody suction line at the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. From the engine compaftment, disconnect the heater supply and return hoses from the underbody combination heater line. 6. Remove the engine cover from the passenger compaftment. 7. Raise and support the vehicle. 8. Disengage the front park brake release cable routing clip from the underbody suction line. Rear Heater-A/C Pluming Connections Remove/Install 9. From under the vehicle, disconnect the flare nut on the underbody liquid line from the threaded 10. From under the vehicle, disconnect the flare nut on the underbody suction line from the threaded fitting on the rear heater-A/C unit suction line. Install plugs in, or tape over all of the opened refrigerant line fittings. 11. From under the vehicle, disconnect the heater supply and return hoses from the rear heater-A/C unit heater lines. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Rear Heater-A/C Unit Plumbing > Page 1037 Underbody Plumbing Remove/Install 12. Remove the nut that secures the underbody plumbing clamp to the front floor panel near the left side of the engine cover opening. 13. Remove the screw that secures the underbody plumbing clamp to the front floor panel reinforcement. 14. Remove the screws that secure the two underbody refrigerant line clamps to the side panel to underbody reinforcement. 15. Remove the underbody plumbing bundle from the vehicle. INSTALLATION 1. From under the vehicle, position the underbody plumbing bundle to the side panel to underbody reinforcement and secure it by loosely installing the two clamp mounting screws. 2. From under the vehicle, connect the heater supply and return hoses to the rear heater-A/C unit heater lines. 3. From under the vehicle, remove the tape or plugs from the suction line fittings at the rear of the underbody plumbing bundle and at the rear heater-A/C unit. Connect the flare nut on the underbody suction line to the threaded fitting on the rear heater-A/C unit suction line. Tighten the fitting to 47 N.m 420 in. lbs. 4. From under the vehicle, remove the tape or plugs from the liquid line fittings at the rear of the underbody plumbing bundle and at the rear heaterA/C unit. Connect the flare nut on the underbody liquid line to the threaded fitting on the rear heaterA/C unit liquid line. Tighten the fitting to 27 N.m 244 in. lbs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation Hose/Line HVAC: Description and Operation SYSTEM OPERATION Refrigerant Line The refrigerant lines and hoses are used to carry the refrigerant between the various air conditioning system components. A barrier hose design with a nylon tube inner hose liner is used for the R-134a air conditioning system on this vehicle. This nylon liner helps to further contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant hoses are made from lightweight aluminum, and use brazeless fittings. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL IN FORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Remove the radiator grille from the vehicle. Suction And Discharge Line Remove/Install 5. Remove the screw that secures the block fitting on the discharge line to the block fitting on the inlet of the condenser, and separate the fitting from the condenser. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Disconnect the flare nut on the suction line from the threaded fitting on the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 8. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from the refrigerant line fittings on the compressor and the refrigerant line manifold. Install the manifold to the compressor. Tighten the mounting screw to 22 N.m (200 in. lbs.). 2. Remove the tape or plugs from the refrigerant line fittings on the suction line and the suction line jumper. Connect the flare nut on the suction line to the threaded fitting on the suction line jumper. Tighten the fitting to 47 N.m (420 in. lbs.). 3. Remove the tape or plugs from the discharge line block fitting and the inlet of the condenser. Connect the liquid line to the condenser inlet and secure the connection with a screw. Tighten the mounting screw to 22 N.m (200 in. lbs.). 4. Reinstall the radiator grille to the vehicle. 5. Plug in the wire harness connector to the high pressure cut-off switch. 6. Connect the battery negative cable. 7. Evacuate the refrigerant system. 8. Charge the refrigerant system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1043 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Liquid Line Remove/Install 3. Remove the screw that secures the block fitting of the liquid line to the inlet of the filter-drier, and separate the fitting from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Remove the radiator grille from the vehicle. 5. Remove the screw that secures the block fitting on the liquid line to the block fitting on the outlet of the condenser, and separate the fitting from the condenser. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Remove the liquid line from the engine compartment. INSTALLATION 1. Remove the tape or plugs from the liquid line block fitting and the outlet of the condenser. Connect the liquid line to the condenser outlet and secure the connection with a screw. Tighten the mounting screw to 22 N.m (200 in. lbs.). 2. Reinstall the radiator grille to the vehicle. 3. Remove the tape or plugs from the liquid line block fitting and the inlet of the filter-drier. Connect the liquid line to the filter-drier inlet and secure the connection with a screw. Tighten the mounting screw to 13.5 N.m (120 in. lbs.). 4. Connect the battery negative cable. 5. Evacuate the refrigerant system. 6. Charge the refrigerant system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1044 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement Suction and Discharge Line Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL IN FORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Remove the radiator grille from the vehicle. Suction And Discharge Line Remove/Install 5. Remove the screw that secures the block fitting on the discharge line to the block fitting on the inlet of the condenser, and separate the fitting from the condenser. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Disconnect the flare nut on the suction line from the threaded fitting on the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 8. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from the refrigerant line fittings on the compressor and the refrigerant line manifold. Install the manifold to the compressor. Tighten the mounting screw to 22 N.m (200 in. lbs.). 2. Remove the tape or plugs from the refrigerant line fittings on the suction line and the suction line jumper. Connect the flare nut on the suction line to the threaded fitting on the suction line jumper. Tighten the fitting to 47 N.m (420 in. lbs.). 3. Remove the tape or plugs from the discharge line block fitting and the inlet of the condenser. Connect the liquid line to the condenser inlet and secure the connection with a screw. Tighten the mounting screw to 22 N.m (200 in. lbs.). 4. Reinstall the radiator grille to the vehicle. 5. Plug in the wire harness connector to the high pressure cut-off switch. 6. Connect the battery negative cable. 7. Evacuate the refrigerant system. 8. Charge the refrigerant system. Suction Line Jumper Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1045 flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the low pressure cut-off switch from the fitting on the suction line jumper. See Low Pressure Cut-Off Switch Replacement for the procedures. 3. Recover the refrigerant from the refrigerant system. Suction Line Jumper Remove/Install 4. Disconnect the flare nut on the suction line from the threaded fitting on the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. If the vehicle is equipped with the optional rear heater-A/C unit, go to Step 7. If not, go to Step 9. 6. Disconnect the flare nut on the underbody plumbing suction line from the threaded fitting on the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Disconnect the flare nut on the underbody plumbing liquid line from the threaded fitting on the liquid line extension. Install plugs in, or tape over all of the opened refrigerant line fittings. 8. Remove the screw that secures the filter-drier to its mounting bracket. 9. Remove the screw that secures the block fitting of the suction line jumper to the outlet of the filter-drier, and separate the fitting from the fitter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 10. Remove the screw that secures the block fitting of the suction line jumper to the expansion valve, and separate the fitting from the expansion valve. Install plugs in, or tape over all of the opened refrigerant line fittings. 11. Remove the suction line jumper from the engine compartment. INSTALLATION 1. Remove the tape or plugs from the block fitting on the suction line jumper and the expansion valve. Position the suction line jumper block fitting to the expansion valve and secure the connection with a screw. Tighten the mounting screw to 22 N.m (200 in. lbs.). 2. Remove the tape or plugs from the block fitting on the suction line jumper and the outlet of the fitter-drier. Position the outlet of the filter-drier to the suction line jumper block fitting and secure the connection with a screw. Tighten the mounting screw to 13.5 N.m (120 in. lbs.). 3. Reinstall the screw that secures the filter-drier to its mounting bracket. Tighten the mounting screw to 8.5 N.m (75 in. lbs.). 4. If the vehicle is equipped with the optional rear heater-A/C unit, go to Step 6. If not, go to Step 8. 5. Remove the tape or plugs from the refrigerant tine fittings on the underbody plumbing liquid line and the liquid line extension. Connect the flare nut on the underbody plumbing liquid line to the threaded fitting on the liquid line extension. Tighten the fitting to 27 N.m (244 in. lbs.). 6. Remove the tape or plugs from the refrigerant line fittings on the underbody plumbing suction line and the suction line jumper. Connect the flare nut on the underbody plumbing suction line to the threaded fitting on the suction line jumper. Tighten the fitting to 47 N.m (420 in. lbs.). 7. Remove the tape or plugs from the refrigerant line fittings on the suction line and the suction line jumper Connect the flare nut on the suction line to the threaded fitting on the suction line jumper. Tighten the fitting to 47 N.m (420 in. lbs.). 8. Install the low pressure cut-off switch to the fitting on the suction line jumper. See Low Pressure Cut-Off Switch. 9. Connect the battery negative cable. 10. Evacuate the refrigerant system. 11. Charge the refrigerant system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1046 Hose/Line HVAC: Service and Repair Rear Heater-A/C Unit Plumbing The rear heater-A/C unit plumbing is used only on models with the optional rear heater-A/C unit. while the formed metal rear heater-A/C unit suction line, liquid line, and heater lines are available for separate service replacement, the rear heater-A/C unit must be removed from the vehicle in order to service them. The molded and straight heater hoses used on the rear heater-A/C unit can be serviced in the vehicle. Any kinks or sharp bends in the rear heater-A/C unit plumbing will reduce the capacity of the entire heating and air conditioning system. Kinks and sharp bends reduce the system flow. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. High temperature coolant is present in the heater plumbing when the engine is operating. Extreme care must be exercised to make sure that each of the plumbing connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Remove the rear heater-A/C unit from the vehicle. 2. Disconnect the rear heater-A/C unit liquid and suction lines from the expansion valve. 3. Disconnect the rear heater-A/C unit heater hoses from the heater inlet and outlet lines. Rear Heater-A/c Plumbing Remove/Install 4. Disengage the seal from the plumbing plate, which is secured to the forward outboard corner of the rear heater-A/C unit lower housing. Push the bottom of the seal out through the top of the plumbing plate from underneath. 5. Remove the plumbing lines and seal as an assembly from the rear heater-A/C unit. 6. If the suction line is being serviced, remove the tie-wraps that secure each end of the insulator to the line, then slide the insulator off. 7. Push the line through the hole from the top of the seal, twisting and turning the line as needed, while pulling it from the bottom of the seal. INSTALLATION 1. Push the line through the hole from the bottom of the seal, twisting and turning the line as needed, while pulling it from the top of the seal. 2. If the suction line is being serviced, slide the insulator onto the line, then secure each end of the insulator to the line with a tie-wrap. 3. Position the plumbing lines and seal as an assembly to the rear heater-A/C unit. 4. Reinstall the seal to the plumbing plate. Push the seal into the plumbing plate from the top until it is fully seated. 5. Connect the rear heater-A/C unit heater hoses to the heater inlet and outlet lines. 6. Connect the rear heater-A/C unit liquid and suction lines to the expansion valve. 7. Reinstall the rear heater-A/C unit in the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1047 Hose/Line HVAC: Service and Repair Underbody Plumbing The underbody plumbing lines are used only on models with the optional rear heater-A/C unit. While the underbody suction line, liquid line, and combination heater line are available for separate service replacement, all lines must be removed from the vehicle as a unit for service. Any kinks or sharp bends in the underbody plumbing will reduce the capacity of the entire heating and air conditioning system. Kinks and sharp bends reduce the system flow. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. High temperature coolant is present in the heater plumbing when the engine is operating. Extreme care must be exercised to make sure that each of the plumbing connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 4. From the engine compaftment, disconnect the underbody liquid line at the liquid line extension and the underbody suction line at the suction line jumper. See Suction Line Jumper in the Replacement. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. From the engine compaftment, disconnect the heater supply and return hoses from the underbody combination heater line. 6. Remove the engine cover from the passenger compaftment. 7. Raise and support the vehicle. 8. Disengage the front park brake release cable routing clip from the underbody suction line. Rear Heater-A/C Pluming Connections Remove/Install 9. From under the vehicle, disconnect the flare nut on the underbody liquid line from the threaded 10. From under the vehicle, disconnect the flare nut on the underbody suction line from the threaded fitting on the rear heater-A/C unit suction line. Install plugs in, or tape over all of the opened refrigerant line fittings. 11. From under the vehicle, disconnect the heater supply and return hoses from the rear heater-A/C unit heater lines. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1048 Underbody Plumbing Remove/Install 12. Remove the nut that secures the underbody plumbing clamp to the front floor panel near the left side of the engine cover opening. 13. Remove the screw that secures the underbody plumbing clamp to the front floor panel reinforcement. 14. Remove the screws that secure the two underbody refrigerant line clamps to the side panel to underbody reinforcement. 15. Remove the underbody plumbing bundle from the vehicle. INSTALLATION 1. From under the vehicle, position the underbody plumbing bundle to the side panel to underbody reinforcement and secure it by loosely installing the two clamp mounting screws. 2. From under the vehicle, connect the heater supply and return hoses to the rear heater-A/C unit heater lines. 3. From under the vehicle, remove the tape or plugs from the suction line fittings at the rear of the underbody plumbing bundle and at the rear heater-A/C unit. Connect the flare nut on the underbody suction line to the threaded fitting on the rear heater-A/C unit suction line. Tighten the fitting to 47 N.m 420 in. lbs. 4. From under the vehicle, remove the tape or plugs from the liquid line fittings at the rear of the underbody plumbing bundle and at the rear heaterA/C unit. Connect the flare nut on the underbody liquid line to the threaded fitting on the rear heaterA/C unit liquid line. Tighten the fitting to 27 N.m 244 in. lbs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure Line ...................................................................................................................................... ...................................................... 35 Nm (25 ft. lbs.) Return Line ..................................................... .......................................................................................................................................... 35 Nm (25 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1056 Brake Fluid: Testing and Inspection CAUTION: The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid. This includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS hydraulic control unit (HCU), and all hydraulic fluid hoses. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1057 Brake Fluid: Service and Repair Always clean the master cylinder filler caps before checking fluid level. If not cleaned, dirt from the caps could enter the fluid. Correct fluid level is to the bottom of the ring indicators on the reservoir. If necessary, add fluid to correct the level. With disc brake equipped vehicles, fluid level in the front brake reservoir will decrease slightly in proportion to normal lining wear. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity ................................................................................................................................. ...................................................... 12.3 L (13.1 Qts.) NOTES: - Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to manufacturing tolerances and refill procedures. - Add 0.9L (1 Qt.) if equipped with an auxiliary rear mounted heater. - Capacities shown include vehicles with air conditioning and/or heavy-duty cooling systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1062 Coolant: Fluid Type Specifications The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37° C (-35° F). The antifreeze concentration must always be a minimum of 44%, year round, in all climates. If percentage is lower than 44%, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. 100 Percent Ethylene-Glycol Should Not Be Used Use of 100 Percent Ethylene-Glycol will cause formation of additive deposits in the system, as the corrosive inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise as high as 149° C (300° F). this temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 % ethylene-glycol freezes at 22° C (-8° F). Propylene-Glycol Formulations Should Not Be Used Propylene-glycol formulations do not meet the required specifications. It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32° C (-26° F), 5 degrees higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at 96.5 kPa (14 PSI), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can result in boil-over and freeze up. Propylene-Glycol also has a poorer heat transfer characteristics than ethylene-glycol. This can increase cylinder head temperatures under certain conditions. Propylene-Glycol/Ethylene-Glycol Mixtures Should Not Be Used Propylene-glycol/ethylene-glycol mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the coling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining the freeze point will not be accurate. Both the refractive index and specific gravity differ between the ethylene-glycol and propylene-glycol. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Coolant Performance Coolant: Description and Operation Coolant Performance ETHYLENE-GLYCOL MIXTURES The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle open ating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37 deg. C 05 deg. F). The anti-freeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7 deg. C (-90 deg. F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. 100 Percent Ethylene-Glycol Should Not Be Used in Chrysler Vehicles Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149 deg. C (300) deg. F). This temperature is hot, enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22 deg. C (-8 deg. F). Propylene-glycol Formulations Should Not Be Used in Chrysler Vehicles Propylene-glycol formulations do not meet Chrysler coolant specifications. It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32 deg. C (-26 deg. F). 5 deg. C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125 deg. C (257 deg. F ) at 96.5 kPa (14 psi), compared to 128 deg. C (263 deg. F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up in Chrysler vehicles, which are designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol/Ethylene-glycol Mixtures Should Not Be Used in Chrysler Vehicles Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Coolant Performance > Page 1065 Coolant: Description and Operation Selection and Additives The presence of aluminum components in the cooling system requires strict corrosion protection. Maintain coolant at specified level with a mixture of ethylene-glycol based antifreeze and water. Chrysler Corporation recommends Mopar Antifreeze or equivalent. If coolant becomes contaminated or looses color, drain and flush cooling system and fill with correctly mixed solution. A 0.25 percent emulsifiable oil is added to the radiator at the factory to prevent solder corrosion. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page 1066 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications > Page 1071 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications > Page 1072 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 32RH ................................................................................................................................................... ................................................. 8.0-8.3L (8.4-8.7 Qt) 46RE ................................................................ ............................................................................................................................. 10.8-11.0L (11.4-11.6 Qt) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1075 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ............................................................................................................ ....................................................... MOPAR ATF +4 Type 9602 or Equivalent Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1076 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid Fluid - Differential: Technical Service Bulletins Differential Cover - Updated Sealer & Fluid NUMBER: 03-08-00 GROUP: Axle & Propeller Shaft DATE: Sep. 5, 2000 SUBJECT: RTV Use On Corporate Axle MODELS: NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH AN 8.25, 9.25, OR C205F CORPORATE AXLE. DISCUSSION: The axle lubricant used in all corporate axles was changed in formulation starting at the beginning of the 1998 model year. The corporate axles involved include: the 8.25 and 9.25 rear axles, and the C205F front axle. The new lubricant in use is SAE 75W-90 p/n 05010320AA. The lubricant change was made as a fuel economy improvement. The new axle lubricant is more chemically aggressive/reactive when in contact with the previous used Room Temperature Vulcanizable (RTV) sealant. Because of this condition, the RTV used in assembly of the pan/cover to the axle housing was revised and improved. When re-sealing axle covers, using the proper sealing material to minimize any potential sealant breakdown is important. The only recommended sealing material for all corporate axle covers is MOPAR RTV Sealant, p/n 05013477M. This RTV is red/orange in color. NOTE: IF SAE 75W-90 LUBRICANT IS USED TO REFILL ANY CORPORATE AXLE, THEN THE RED/ORANGE MOPAR RTV SEALANT, P/N 05013477AA, SHOULD BE USED TO SEAL THE COVER TO THE AXLE HOUSING. To optimize sealant performance and enhance adhesion, flanges should be clean and free of residual lubricant. The mating flanges should first be cleaned of any excess old RTV using a plastic putty knife. Final cleaning/degreasing shall be done by spraying MOPAR Brake Parts Cleaner, p/n 04549623, on the carrier and cover flanges, followed by a wipe with a clean dry cloth. Care should be taken to avoid spraying the parts cleaner inside the carrier. Once the RTV has been applied, the axle cover is to be installed to the housing within 3 to 5 minutes to prevent skinning over of the RTV. NOTE: IF THE AXLE COVER IS NOT INSTALLED WITHIN THE 3 TO 5 MINUTE TIME FRAME, THE CARRIER COVER FACE MUST BE RECLEANED AND NEW RTV APPLIED, OR ADHESION QUALITY WILL BE COMPROMISED. Immediately install the cover attaching bolts and tighten them to the specified torque to prevent a shimming effect by the RTV. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid > Page 1081 Fluid - Differential: Technical Service Bulletins Differential - Lubricant & Sealing Requirements NO: 03-02-98 GROUP: Axle And Propshaft DATE: Apr. 3, 1996 SUBJECT: 8-1/4 - 9-1/4 Axle Lubricant And Sealing Requirements MODELS: 1998 (AB) Ram Van 1998 (AN) Dakota 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1998 (XJ) Cherokee DISCUSSION: With the introduction of the 1998 model year, the axle lubricant in the 8-1/4 and 9-1/4 axles was changed in formulation to improve fuel economy. When adding lubricant or if service is performed that requires new lubricant use 75W90 p/n 5010320AA. This lubricant is more aggressive toward RTV sealants than previously used axle lubricants. When resealing the axle cover, using the proper sealing material to minimize any potential fluid foaming and/or seal breakdown is important. Currently the only recommended sealing material for mall axle covers or transmission pans is MOPAR RTV Sealant (grey in color) p/n 82300234. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity 8 1/4 ..................................................................................................................................................... ........................................................ 2.22L (4.7 pints) With TRAC-LOK .............................................. ..................................................................................................................... include 5 oz. friction modifier 9 1/4 ....................................................................................................................................... ...................................................................... 2.32L (4.9 pints) With TRAC-LOK ................................ ................................................................................................................................... include 5 oz. friction modifier 248RBI ....................................................................................................................... ............................................................................... 2.96L (6.25 pints) With TRAC-LOK ..................... .............................................................................................................................................. include 6 oz. friction modifier Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1084 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Grade ................................................................................................................................................... ................................................................... API GL-5 Viscosity .............................................................................................................................................. ........................................................................... 90W TRAC-LOK differentials require the specified amount of friction modifier. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1085 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Without Filter Change .......................................................................................................................... ............................................................. 4.2L (4.5 Qt) Capacity shown is without filter. When replacing filter, additional oil may be needed Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1090 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................... SH or SH/CD or Above Above 0°F (-18°C).............................................. ........................................................................................................................................................ 10W-30 Below 32°F (0°C).................................................................................................................... ..................................................................................... 5W-30 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1091 Engine Oil: Service Precautions WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1092 Engine Oil: Description and Operation ENGINE OIL SPECIFICATION. CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. API SERVICE GRADE CERTIFIED Engine Oil Container Standard Notations Use an engine oil that is API Service Grade Certified. Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans. SAE VISCOSITY Temperature/Engine Oil Viscosity An SAE viscosity grade is used to specify the viscosity of engine oil. SAE 1OW-30 specifies a multiple viscosity engine oil. When choosing an engine oil, consider the range of temperatures the vehicle will be operated in before the next oil change. Select an engine oil that is best suited to your area's particular ambient temperature range and variation. ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CON-SERVING is located on the label of an engine oil container. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1093 Engine Oil: Testing and Inspection CRANKCASE OIL LEVEL INSPECTION CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable oil level is in the SAFE RANGE on the engine oil dipstick. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately ten minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the SAFE RANGE area on the dipstick. ENGINE OIL PRESSURE 1. Remove oil pressure sending unit. 2. Install Oil Pressure Line and Gauge Tool C-3292. Start engine and record pressure. Refer to Oil Pressure in Engine Specifications for the proper pressures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1094 Engine Oil: Service and Repair ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in the Maintenance Schedule. TO CHANGE ENGINE OIL Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and amount of engine oil described. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1099 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1100 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1101 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Capacity ............................................................................................................................................... ....................................................... 1.28 L (2.7 pints) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 1104 Power Steering Fluid: Fluid Type Specifications The recommended lubricant is Mopar Power Steering Fluid. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Single Capacity ........................................................................................................................................................... 0.96 kg (33.86 oz. or 2.12 lbs) R134a Dual Capacity ............................................................................................................................................................. 1.30 kg (45.85 oz. or 2.87 lbs) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1109 Refrigerant: Fluid Type Specifications Hydrofluorocarbon (HFC), ................................................................................................................... ............................................... R-134a liquefied gas Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1110 Refrigerant: Description and Operation SYSTEM OPERATION The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 added to an R-134a refrigerant system will cause compressor failure, refrigerant oil sludge or poor air conditioning system performance. In addition, the PolyAlkylene Glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the compressor identifying to service technicians that the air conditioning system is equipped with R-134a. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System ........................................................................................................................................ ........................................ (Front only) 236 ml 8.0 oz. Total System ........................................................................................................................................ .................................. (Front & Rear) 295 ml 10.0 oz. Condenser ........................................................................................................................................... ................................................................ 30 ml 1.0 oz. Evaporator ........................................................................................................................................... ............................................................... 60 ml 2.0 oz. Filter-Drier ...................................................... ................................................................................................................................................... 30 ml 1.0 oz. Compressor ............................................................................................................................................. Drain and measure the oil from the old compressor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1115 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. ......................................................................... SP-10 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1116 Refrigerant Oil: Service and Repair Refrigerant Oil Level Refrigerant Oil Capacities When an air conditioning system is assembled at the factory, all components except the compressor and the combination coil, if the vehicle is so equipped, are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the compressor and the combination coil is dispersed throughout the refrigerant system. The combination coil, evaporator, filter-drier, condenser, and compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of oil in the refrigerant system. This ensures proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the air conditioning system. It will not be necessary to check the oil level in the compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when a filter-drier, evaporator coil, combination coil, or condenser are replaced. See the Refrigerant Oil Capacities chart. When a compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures W/ Four Wheel Antilock Brakes ABS system bleeding requires conventional bleeding methods plus use of the DRB scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. W/ Rear Wheel Antilock Brakes GENERAL INFORMATION RWAL brake bleeding can be performed manually, or with pressure bleeding equipment. Use Mopar DOT 3 brake fluid, or an equivalent meeting SAE J1703-F and DOT 3 standards, to fill and bleed the brake system. Bleed only one brake component at a time. Recommended bleed sequence is: master cylinder - combination valve - rear antilock valve - left rear wheel - right rear wheel - right front wheel - left front wheel MANUAL BLEEDING Use a bleed hose at each caliper/cylinder bleed screw. Attach one end of the hose to the bleed screw and insert the opposite end in glass container partially filled with brake fluid. A glass container makes it easier to see air bubbles as they exit the bleed hose. Be sure the end of the bleed hose remains immersed in fluid. This prevents air from being drawn back into the system. Do not allow the master cylinder to run out of fluid when bleeding the brakes. An empty cylinder will allow air to be drawn back into the system. Check fluid level frequently during bleeding operations. Be sure to tighten each brake line fitting, or bleed screw once bleeding is completed. Loose fittings and bleed screws allows air to enter the system. PRESSURE BLEEDING If pressure bleeding equipment will be used, the front brake metering valve will have to be held open to bleed the front brakes. The valve stem is located in the forward end of the combination valve. The stem must either be pressed inward, or held outward slightly. a spring clip tool or helper is needed to hold the valve stem in position. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15 - 20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 1121 Brake Bleeding: Service and Repair Base Brake System Bleeding GENERAL INFORMATION Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. Bleed only one brake component at a time in the following sequence: master cylinder - combination valve - right rear wheel - left rear wheel - right front wheel - left front wheel MANUAL BLEEDING 1. Remove reservoir filler caps and fill reservoir with Mopar, or equivalent quality DOT 3 brake fluid. 2. If calipers, or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. Bleed Hose Setup 3. Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. PRESSURE BLEEDING Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15 - 20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Use adapter provided with the equipment or Adapter 6921 or equivalent. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: The airbag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the airbag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the airbag and possible personal injury. The fasteners, screws, and bolts, originally used for the airbag components, have special coatings and are specifically designed for the airbag system. They must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books . Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 1125 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Description and Operation Circuit Breaker: Description and Operation SYSTEM OPERATION An automatic resetting circuit breaker in the junction block is used to protect the power seat system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck seat adjuster. The circuit breaker cannot be repaired and, if faulty or damaged, it must be replaced. An automatic resetting circuit breaker in the junction block is used to protect the power window system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck window glass or regulator. The circuit breaker cannot be repaired and, if faulty, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Description and Operation > Page 1130 Circuit Breaker: Testing and Inspection 1. Locate the correct circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Description and Operation > Page 1131 Circuit Breaker: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the end cap from the driver side end of the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel End Cap. Junction Block 3. Unplug the circuit breaker from the junction block. 4. Install the circuit breaker by aligning its terminals with the cavities in the junction block and pushing the circuit breaker firmly into place. 5. Connect the battery negative cable. 6. Test the circuit breaker operation. 7. Reinstall the end cap on the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel End Cap. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Power Distribution Center > Page 1136 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations Power Distribution Center, Battery, Windshield Washer Reservoir Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Data Link Connector As a functional test, the MIL (check engine) illuminates at key-on before engine cranking. Whenever the Powertrain Control Module (PCM) sets a Diagnostic Trouble Code (DTC) that affects vehicle emissions, it illuminates the MIL. If a problem is detected, the PCM sends a message to the instrument cluster to illuminate the lamp. The PCM illuminates the MIL only for DTC's that affect vehicle emissions. There are some monitors that may take two consecutive trips, with a detected fault, before the MIL is illuminated. The MIL stays on continuously when the PCM has entered a Limp-In mode or identified a failed emission component. Also, the MIL either flashes or illuminates continuously when the PCM detects active engine misfire. Additionally, the PCM may reset (turn off) the MIL when one of the following occur: ^ PCM does not detect the malfunction for 3 consecutive trips (except misfire and Fuel system Monitors). ^ PCM does not detect a malfunction while performing three successive engine misfire or fuel system tests. The PCM performs these tests while the engine is operating within ± 375 RPM of and within 10 % of the load of the operating condition at which the malfunction was first detected. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1144 Malfunction Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative malfunction indicator (Check Engine) lamp condition. If the lamp comes on and stays on with the engine running, refer to Powertrain Management/Computers and Control Systems/Testing and Inspection. See: Powertrain Management/Computers and Control Systems/Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the malfunction indicator lamp falls to light during the bulb test (about two seconds after the ignition switch is turned to the On position), replace the malfunction indicator lamp bulb with a known good unit. If the indicator lamp still fails to operate, diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For further diagnosis of the malfunction indicator lamp and the instrument cluster circuitry, refer to Instrument Panel/Testing and Inspection. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation The temporary spare tire is designed for emergency use only. The original tire should be repaired and reinstalled at the first opportunity, or replaced with a new. Do not exceed speeds of 50 MPH when the temporary spare tire is in use on the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 1158 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 1159 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 1160 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions Oil Pressure Sensor: Technical Service Bulletins Engine Controls/Fuel System - Manual Revisions NUMBER: 26-01-99C GROUP: Miscellaneous DATE: January, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Powertrain 2.5L. 3.9L, 5.2L, 5.9L, 8.0 SFI, Mechanical Injected Diesel Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revision to the Table of Contents Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1164 vi Revision to the Trouble Code Test menu Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1165 538 Revision to the Oil Pressure Sensor test 589, 589A through 589F Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1166 589 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1167 589A Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1168 589B Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1169 589C Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1170 589D Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1171 589E Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1172 589F Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 18-19-98 > Apr > 98 > Customer Interest for Wheels: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 18-19-98 > Apr > 98 > Customer Interest for Wheels: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 1182 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 18-19-98 > Apr > 98 > Customer Interest for Wheels: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 1183 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 18-19-98 > Apr > 98 > Customer Interest for Wheels: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 1184 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > System Information > Service and Repair > Rear Cargo Doors Rear Door Exterior Handle: Service and Repair Rear Cargo Doors EXTERIOR HANDLE REMOVAL 1. Open the rear cargo door. 2. Remove the trim panel from the door inner panel. Fig. 4 Fig. 5 3. Disconnect the outside door handle rod from the latch lever (Fig. 4) and (Fig. 5). 4. Remove the nuts that attach the handle to the door outer panel. Remove the handle from the door. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > System Information > Service and Repair > Rear Cargo Doors > Page 1188 INSTALLATION 1. Position the handle on the door outer panel with the handle rod inserted in the opening. Insert the handle studs into the panel holes. 2. Attach the handle rod to the latch. 3. Install the nuts that attach the handle to the door outer panel. 4. Install the door trim panel. REAR CARGO DOOR OUTSIDE HANDLE/LATCH LEVER 1. Insert a 4 mm (5/32 in.) hex-wrench through the adjustment slot and into the latch release lever adjustment screw. Loosen the adjustment screw. 2. Depress and release the door outside handle latch release button several times. 3. Tighten the adjustment screw to 3 N.m (30 in. lbs.) torque. 4. Test the door handle for correct operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > System Information > Service and Repair > Rear Cargo Doors > Page 1189 Rear Door Exterior Handle: Service and Repair Dual Cargo Doors EXTERIOR HANDLE REMOVAL 1. Open the cargo doors. 2. Remove the trim panel from the right door. Fig. 4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > System Information > Service and Repair > Rear Cargo Doors > Page 1190 Fig. 5 3. Disconnect the outside handle latch rod from the latch lever (Fig. 4) and (Fig. 5). 4. Remove the nuts that attach the handle to the door panel. Remove the handle from the door. INSTALLATION 1. Position the handle on the door panel with the handle latch rod inserted in the opening. Insert the handle studs into the panel holes. 2. Attach the handle latch rod to the latch lever. 3. Install the nuts that attach the handle to the door panel. 4. Install the door trim panel. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Component Information > Description and Operation Blower Motor Switch: Description and Operation SYSTEM OPERATION Front The front blower motor is controlled by a four position rotary-type blower motor switch, mounted in the heater-only or heater-A/C control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned off by selecting the Off position with the heater-A/C mode control switch knob. The blower motor switch directs the blower motor ground path from the mode control switch to the blower motor resistor, or directly to ground through the high speed blower motor relay, as required to achieve the selected blower motor speed. The front blower motor switch cannot be repaired and, if faulty or damaged, the entire heater-only or heater-A/C control unit must be replaced. The blower motor switch knob is serviced separately Rear The optional rear heater-A/C unit blower motor is controlled by a four position rotary-type blower motor switch, mounted in the accessory switch plate located to the right of the heater-A/C control on the instrument panel. The switch allows the selection of one of three blower motor speeds and an Off position. The rear blower motor switch directs the blower motor ground path to the blower motor resistor, or directly to ground through the high speed blower motor relay as required to achieve the selected blower motor speed. The rear blower motor switch cannot be repaired and, if faulty or damaged, it must be replaced. The rear blower motor switch knob is serviced separately The rear blower motor switch also has a replaceable incandescent-type illumination lamp bulb. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Component Information > Description and Operation > Page 1193 Blower Motor Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR-BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Front 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the heater-A/C control from the instrument panel. See Heater-A/C Control Replacement for the procedures. Check for continuity between the ground circuit (Z1V) cavity of the heater-A/C mode control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 2. With the heater-A/C control wire harness connector unplugged, place the heater-A/C mode control switch knob in any position except the Off position. Check for continuity between the two ground circuit terminals in the mode switch receptacle of the heater-A/C control. There should be continuity. If OK, go to Step 4. If not OK, replace the faulty heater-A/C control unit. 3. Check for continuity between the ground circuit (C 72) cavities of the heater-A/C mode control wire harness connector and the heater-A/C blower speed switch wire harness connector. There should be continuity. If OK, go to Step 5. If not OK, repair the open circuit as required. 4. Check for continuity between the ground circuit (C 72) terminal and each of the blower motor driver circuit terminals in the blower speed switch receptacle of the heater-A/C control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the heater-A/C control blower speed switch wire harness connector and the front blower motor resistor or the front high speed blower motor relay as required. If not OK, replace the faulty heater-A/C control unit. Rear 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the accessory switch plate from the instrument panel. Refer to Accessory Switch Plate in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel for the procedures. Check for continuity between the ground circuit cavity of the rear blower motor switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 2. With the rear blower motor switch wire harness connector unplugged, place the rear blower motor switch knob in any position except the Off position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the rear blower motor switch as you move the blower motor switch knob to each of the three speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the rear blower driver circuits between the rear blower motor switch wire harness connector and the rear blower motor resistor or the rear high speed blower motor relay as required. If not OK, replace the faulty rear blower motor switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Component Information > Description and Operation > Page 1194 Blower Motor Switch: Service and Repair The rear blower motor switch is used only on models with the optional rear heater-A/C unit. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the accessory switch plate from the instrument panel. Refer to Accessory Switch Plate in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel procedures. Rear Blower Motor Remove/Install 3. Rotate the illumination lamp socket counterclockwise to disengage it from the back of the switch housing. 4. Pull the knob off of the blower motor switch stem from the front of the accessory switch plate. 5. With a small thin-bladed screwdriver, gently pry the sides of the accessory switch plate to release the two snap clips on each side of the rear blower motor switch housing. 6. Remove the rear blower motor switch from the back of the accessory switch plate. INSTALLATION 1. Position the rear blower motor switch on the back of the accessory switch plate. 2. Firmly and evenly press the rear blower motor switch into the back of the accessory switch plate until it snaps into place. Be certain that all of the switch snap clip retainers are fully engaged. 3. Reinstall the knob onto the rear blower motor switch stem from the front of the accessory switch plate. Be certain to index the flat on the switch stem with the flat in the hub of the knob. 4. Reinstall the illumination lamp socket to the back of the rear blower motor switch housing. 5. Reinstall the accessory switch plate in the instrument panel. Refer to Accessory Switch Plate in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel procedures. 6. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 1205 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 1206 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 1207 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 > Steering/Suspension Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 > Steering/Suspension Wander Diagnosis/Repair > Page 1213 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 > Steering/Suspension Wander Diagnosis/Repair > Page 1214 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 > Steering/Suspension Wander Diagnosis/Repair > Page 1215 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised Wheel Bearing: All Technical Service Bulletins Steering Wander - Diagnosis and Correction Revised NUMBER: 19-07-00 GROUP: Steering DATE: September 22, 2000 SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering wander. MODELS: 1998-2001 (AB) Ram Van/Wagon SYMPTOM/CONDITION: Steering Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering wander can be created by a number of different conditions including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying extra added weight (e.g. tool boxes). ^ Steering and/or suspension components that are worn or damaged. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: UNDER CERTAIN ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. DIAGNOSIS: 1. Verify that the vehicle is not equipped with non-factory installed options or equipment that may cause the vehicle to wander such as heavy toolboxes or hardware that may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended may cause the vehicle to wander and should be replaced before continuing with the diagnosis. 3. Inflate all tires to the pressure specified in the Tire Inflation Pressure sheet (located in the glove box). NOTE: TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS BUT, ONLY IF THE VEHICLE IS AT CURB OR LIGHT LOAD CONDITIONS. 4. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without cross wind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Proceed to the next step if the vehicle exhibits a steering wander condition. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-3 OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, ETC.). 5. Raise the vehicle on an appropriate lift. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised > Page 1220 6. Secure a dial indicator to the lower control arm. Position the dial indicator so that the tip of the indicator contacts the inside face of the rotor (Figure 1). 7. Place your hands at the top and bottom of the tire/wheel assembly and push the tire/wheel assembly inboard (Figure 2). Zero the dial indicator. With your hands at the top and bottom of the tire/wheel assembly, pull the tire/wheel assembly outboard (Figure 3). Record the dial indicator reading. Perform this procedure on both front wheel bearings and proceed to the next step if the wheel bearing endplay exceeds 0.025 - 0.076 mm (0.001 - 0.003 in.). Proceed to Step 9 if wheel-bearing endplay on both front wheel bearings are within specifications. NOTE: WHEEL BEARING INSPECTION AND ADJUSTMENT IS ONLY REQUIRED ON WHEEL BEARINGS EXCEEDING 0.025 - 0.076 MM (0.001 - 0.003 IN.) ENDPLAY. 8. Remove the wheel bearing protective end cap, cotter pin, nut lock, nut, and washer from the spindle. Inspect the wheel bearings. If it is determined that wheel bearing replacement is necessary, refer to the appropriate Ram Van/Wagon Service Manual, Group 02, Wheel Bearings, for removal and installation information. Reinstall the wheel bearings, washer, and adjustment nut if the wheel bearings pass the inspection. 9. Using a torque wrench, tighten the wheel bearing adjustment nut to 54 N.m (40 ft. lbs.) while rotating the tire/wheel assembly. Stop the wheel from rotating and loosen the nut. Using the procedure identified in Steps 6 and 7 to measure endplay, adjust the front wheel bearing endplay until 0.025 - 0.076 mm (0.001 - 0.003 in.) endplay has been achieved. Install the nut lock and a new cotter pin. 10. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual. Any worn steering and/or suspension component must be replaced prior to performing an alignment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised > Page 1221 11. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the chart for proper alignment specifications. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised Wheel Bearing: All Technical Service Bulletins Steering Wander - Diagnosis and Correction Revised NUMBER: 19-07-00 GROUP: Steering DATE: September 22, 2000 SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering wander. MODELS: 1998-2001 (AB) Ram Van/Wagon SYMPTOM/CONDITION: Steering Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering wander can be created by a number of different conditions including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying extra added weight (e.g. tool boxes). ^ Steering and/or suspension components that are worn or damaged. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: UNDER CERTAIN ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. DIAGNOSIS: 1. Verify that the vehicle is not equipped with non-factory installed options or equipment that may cause the vehicle to wander such as heavy toolboxes or hardware that may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended may cause the vehicle to wander and should be replaced before continuing with the diagnosis. 3. Inflate all tires to the pressure specified in the Tire Inflation Pressure sheet (located in the glove box). NOTE: TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS BUT, ONLY IF THE VEHICLE IS AT CURB OR LIGHT LOAD CONDITIONS. 4. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without cross wind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Proceed to the next step if the vehicle exhibits a steering wander condition. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-3 OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, ETC.). 5. Raise the vehicle on an appropriate lift. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised > Page 1227 6. Secure a dial indicator to the lower control arm. Position the dial indicator so that the tip of the indicator contacts the inside face of the rotor (Figure 1). 7. Place your hands at the top and bottom of the tire/wheel assembly and push the tire/wheel assembly inboard (Figure 2). Zero the dial indicator. With your hands at the top and bottom of the tire/wheel assembly, pull the tire/wheel assembly outboard (Figure 3). Record the dial indicator reading. Perform this procedure on both front wheel bearings and proceed to the next step if the wheel bearing endplay exceeds 0.025 - 0.076 mm (0.001 - 0.003 in.). Proceed to Step 9 if wheel-bearing endplay on both front wheel bearings are within specifications. NOTE: WHEEL BEARING INSPECTION AND ADJUSTMENT IS ONLY REQUIRED ON WHEEL BEARINGS EXCEEDING 0.025 - 0.076 MM (0.001 - 0.003 IN.) ENDPLAY. 8. Remove the wheel bearing protective end cap, cotter pin, nut lock, nut, and washer from the spindle. Inspect the wheel bearings. If it is determined that wheel bearing replacement is necessary, refer to the appropriate Ram Van/Wagon Service Manual, Group 02, Wheel Bearings, for removal and installation information. Reinstall the wheel bearings, washer, and adjustment nut if the wheel bearings pass the inspection. 9. Using a torque wrench, tighten the wheel bearing adjustment nut to 54 N.m (40 ft. lbs.) while rotating the tire/wheel assembly. Stop the wheel from rotating and loosen the nut. Using the procedure identified in Steps 6 and 7 to measure endplay, adjust the front wheel bearing endplay until 0.025 - 0.076 mm (0.001 - 0.003 in.) endplay has been achieved. Install the nut lock and a new cotter pin. 10. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual. Any worn steering and/or suspension component must be replaced prior to performing an alignment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised > Page 1228 11. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the chart for proper alignment specifications. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 1229 Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front REMOVAL 1. Lock brake pedal in up position. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 4. Remove disc brake caliper. 5. Remove the dust cap, cotter pin, and remaining hub components from spindle. 6. Carefully slide the hub/rotor from spindle. CAUTION: Use care to prevent inner wheel bearing and seal from contacting spindle threads during removal). 7. Remove the seal and inner wheel bearing from the hub/rotor. Remove the inner bearing races from hub/rotor with a pin punch. INSTALLATION 1. Install the new bearing cup(s) with an appropriate installation tool. 2. Apply a coating of Mopar (R) Wheel Bearing Grease to inner surface area of hub. Install inner wheel bearing and new bearing seal. 3. Inspect bearing and seal contact surfaces on spindle for burrs and or roughness. 4. Remove all rough contact surfaces from spindle. Apply a coating of lubricant. CAUTION: Use care to prevent inner wheel bearing and seal from contacting spindle threads during installation. 5. Carefully slide the hub/rotor onto spindle. Install outer wheel bearing, washer and retaining nut. 6. Tighten the nut to 41 - 54 Nm (30 - 40 ft. lbs.) to preload bearing while rotating the hub/rotor. Stop hub/rotor and loosen nut to completely release bearing preload torque. Tighten the nut finger-tight and install the nut lock. Install a new cotter pin. 7. The adjustment (above) should have 0.254 - 0.0762 mm (0.001 - 0.003 inch) end play. 8. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. 9. Install disc brake caliper. 10. Install the wheel and tire assembly and lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1232 Wheel Bearing: Service and Repair Rear 8 1/4 and 9 1/4 Axles REMOVAL 1. Remove axle shaft. Axle Seal Removal 2. Remove axle shaft seal from the end of the axle tube with a small pry bar. NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. Axle Shaft Bearing Removal Tool 3. Remove the axle shaft bearing from the axle tube with Bearing Removal Tool Set 6310, using Adapter Foot 6310-9. INSTALLATION NOTE: Do not install the original axle shaft seal. Always install a new seal. 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1233 Axle Shaft Seal And Bearing Installation 2. Install the axle shaft bearing with Installer C-4198 and Handle C-4171. Ensure that the bearing part number is against the installer. Verify that the bearing in installed straight and the tool fully contacts the axle tube when seating the bearing. 3. Install a new axle seal with Installer C-4076-B and Handle C-4735-1. When the tool contacts the axle tube, the seal is installed to the correct depth. 4. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 5. Install the axle shaft. With 9 1/4 Axle REMOVAL 1. Remove axle shaft. Axle Seal Removal 2. Remove axle shaft seal from the end of the axle tube with a small pry bar. Axle Shaft Bearing Removal Tool Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1234 3. Remove the axle shaft bearing from the axle tube with Bearing Removal Tool C-4828. INSTALLATION NOTE: Do not install the original axle shaft seal. Always install a new seal. 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. Axle Shaft Seal And Bearing Installation 2. Install the axle shaft bearing with Installer C-4826-1 and Handle C-4171. Ensure that the bearing part number is against the installer. Verify that the bearing in installed straight and the tool fully contacts the axle tube when seating the bearing. 3. Install a new axle seal with Installer C-4826-1, Adapter C-4826-2, and Handle C-4171. When the tool contacts the axle tube, the seal is installed to the correct depth. 4. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 5. Install the axle shaft. 248 RBI Axle REMOVAL 1. Remove wheel and tire assembly. 2. Remove brake drum. 3. Remove the axle shaft. 4. Remove the lock wedge and adjustment nut. Use Socket DD-1241-JD to remove the adjustment nut. 5. Remove the hub assembly. The outer axle bearing will slide out as the hub is being removed. 6. Remove inner grease seal and discard. Use Installer 5064 and Handle C-4171 to drive grease seal and inner axle bearing from the hub. 7. Remove the bearing cups from the hub bore. Use a brass drift, or an appropriate removal tool, to tap out the cups. INSTALLATION 1. Thoroughly clean both axle bearings and interior of the hub with an appropriate cleaning solvent. 2. Install the bearing cups. Use Installer 8151 and Handle C-4171 to install the bearing cups. 3. Apply lubricant to surface area of the bearing cup. 4. Install the inner axle bearing in the hub. 5. Install a new bearing grease seal. Use Installer 8149 and Handle C-4171 to install the grease seal. 6. Inspect the bearing and seal contact surfaces on the axle tube spindle for burrs and/or roughness. Remove all the rough contact surfaces from the axle spindle. Apply a coating of multi-purpose NLGI, grade 2, EP-type lubricant to the axle. CAUTION: Use care to prevent the bearing grease seal from contacting the axle tube spindle threads during installation. Otherwise, the seal could be damaged. 7. Carefully slide the hub onto the axle. 8. Install the outer axle bearing. 9. Install the hub bearing adjustment nut. Use Socket DD-1241-JD to install the adjustment nut. 10. Tighten the adjustment nut to 163-190 Nm (120-140 ft. lbs.) while rotating the wheel. 11. Loosen the adjustment nut 1/8 of-a-turn to provide 0.001-inch to 0.010-inch wheel bearing end play. 12. Tap the locking wedge into the spindle keyway and adjustment nut. Try to ensure that the locking wedge is installed into a new position in the adjustment nut. 13. Install the axle shaft. 14. Install the brake drum. 15. Install the wheel and tire assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Wheel Torque Sequence - Master Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 1239 Wheel Fastener: Specifications Lug Nut Torque 15 Inch 5 Stud Wheel ........................................................................................................................................................... 109 - 150 Nm (80 - 110 ft. lbs.) 16 Inch 8 Stud Wheel ......................................................................................................................................................... 163 - 203 Nm (120 - 150 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1240 Wheel Fastener: Service and Repair REMOVAL 1. Remove wheel and tire assembly. 2. Remove disc brake rotor. 3. Place rotor on flat surface and drive studs out of the with a hammer and punch. INSTALLATION 1. Turn the rotor over and place in a vise. 2. Drive new studs into the rotor with hammer and punch. 3. Install rotor. 4. Install wheel and tire assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair Access Cover: Service and Repair NOTE: The engine cover is attached with screws at the rear and with latches at the dash extension. REMOVAL 1. Remove screws attaching holddown brackets to floor pan. 2. Disengage latches from dash extension. 3. Remove engine cover from vehicle. INSTALLATION 1. Position engine cover on floor pan. 2. Ensure seal is seated correctly. 3. Position holddown brackets on cover and install screws in floor pan finger tight. 4. Engage latches with dash panel extension. 5. Tighten screws attaching cover to floor pan. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi) from cylinder to cylinder. If cylinder(s) have abnormally low compression pressures, repeat procedure. - If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a problem in the cylinder. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should NOT be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1249 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. Minimum cylinder compression pressure is 689 kPa (100 psi). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications BEARING DIAMETERS: No.1 ..................................................................................................................................................... .......... 50.800 - 50.825 mm (2.0000 - 2.0010 inch) No.2 ..................................................................... .......................................................................................... 50.394 - 50.419 mm (1.9840 - 1.9850 inch) No.3 ............................................................................................................................................ ................... 50.013 - 50.038 mm (1.9690 - 1.9700 inch) No.4 ............................................................ ................................................................................................... 49.606 - 49.632 mm (1.9530 1.9540 inch) No.5 ................................................................................................................................ ............................... 39.688 - 39.713 mm (1.5625 - 1.5635 inch) DIAMETRICAL CLEARANCE: Standard ............................................................................................................................................................ 0.0254 - 0.0762 mm 10.001 - 0.003 inch) Max. Allowable .................................................................. ........................................................................................................... 0.127 mm (0.005 inch) BEARING JOURNAL DIAMETER: No.1 ..................................................................................................................................................... .......... 50.749 - 50.775 mm (1.9980 - 1.9990 inch) No.2 ..................................................................... .......................................................................................... 50.343 - 50.368 mm (1.9820 - 1.9830 inch) No.3 ............................................................................................................................................ ................... 49.962 - 49.987 mm (1.9670 - 1.9680 inch) No.4 ............................................................ ................................................................................................... 49.555 - 49.581 mm (1.9510 1.9520 inch) No.5 ................................................................................................................................ ............................... 39.637 - 39.662 mm (1.5605 - 1.5615 inch) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Page 1254 Camshaft Bearing: Service and Repair REMOVAL NOTE: This procedure requires that the engine is removed from the vehicle. 1. With engine completely disassembled, drive out rear cam bearing core hole plug. Camshaft Bearings Removal?installation With Tool C-3132-A 2. Install proper size adapters and horseshoe washers (part of Camshaft Bearing Remover/Installer Tool C-3132-A) at back of each bearing shell. Drive out bearing shells. INSTALLATION 1. Install new camshaft bearings with Camshaft Bearing Remover/Installer Tool C-3132-A by sliding the new camshaft bearing shell over proper adapter. 2. Position rear bearing in the tool. Install horseshoe lock and by reversing removal procedure, carefully drive bearing shell into place. 3. Install remaining bearings in the same manner. Bearings must be carefully aligned to bring oil holes into full register with oil passages from the main bearing. If the camshaft bearing shell oil holes are not in exact alignment, remove and install them correctly. Install a new core hole plug at the rear of camshaft. Be sure this plug does not leak. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt ....................................................................................................................... .................................................... 68 Nm (50 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Bearing Diameter No.1 2.000 - 2.001 in No.2 1.984 - 1.985 in No.3 1.969 - 1.970 in No.4 1.953 - 1.954 in No.5 1.5625 - 1.5635 in Bearing Journal Diameter No.1 1.998 - 1.999 in No.2 1.982 - 1.983 in No.3 1.967 - 1.968 in No.4 1.951 - 1.952 in No.5 1.5605 - 1.5615 in Bearing to Journal Clearance Standard 0.001 - 0.003 in Service Limit 0.005 in Camshaft End Play 0.002 - 0.010 in Lift (@ zero lash) - Intake 0.410 in Lift (@ zero lash) - Exhaust 0.417 in Exhaust Valve Closes (ATDC) 33 deg Opens (BBDC) 56 deg Duration 269 deg Intake Valve Closes (ATDC) 62 deg Opens (BBDC) 17 deg Duration 249 deg Valve Overlap 41 deg Camshaft Bolt 50 ft.lb Camshaft Thrust Plate Bolts 210 in.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement Camshaft: Service and Repair Camshaft Replacement Camshaft And Sprocket Assembly NOTE: The camshaft has an integral oil pump and distributor drive gear. REMOVAL 1. Remove the radiator. Refer to Cooling System for the correct procedures. 2. Remove the A/C Condenser (if equipped) 3. Remove the engine cover. 4. Remove intake manifold. 5. Remove cylinder head covers. 6. Remove timing case cover and timing chain. 7. Remove rocker arms. 8. Remove push rods and tappets. Identify each part so it can be installed in its original location. Timing Chain Oil Tap Installation 9. Remove distributor and lift out the oil pump and distributor drive shaft. 10. Remove camshaft thrust plate, note location of oil tab. 11. Install a long bolt into front of camshaft to facilitate removal of the camshaft. Remove camshaft, being careful not to damage cam bearings with the cam lobes. INSTALLATION 1. Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 51 mm (2 inches) of its final position in cylinder block. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 1263 Camshaft Holding Tool C-3509 (Installed Position) 2. Install Camshaft Gear Installer Tool C-3509 with tongue back of distributor drive gear. 3. Hold tool in position with a distributor lockplate bolt. This tool will restrict camshaft from being pushed in too far and prevent knocking out, the welch plug in rear of cylinder block. Tool should remain installed until the camshaft and crankshaft sprockets and timing chain have been installed. 4. Install camshaft thrust plate and chain oil tab. Make sure tang enters lower right hole in thrust plate. Tighten bolts to 24 Nm (210 inch lbs.) torque. Top edge of tab should be flat against thrust plate in order to catch oil for chain lubrication. 5. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores. 6. Place timing chain around both sprockets. 7. Turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in camshaft sprocket. 8. Lift sprockets and chain (keep sprockets tight against the chain in position as described). Alignment Of Timing Marks 9. Slide both sprockets evenly over their respective shafts and use a straightedge to check alignment of timing marks. 10. Install the camshaft bolt/cup washer. Tighten bolt to 68 Nm (50 ft. lbs.) torque. 11. Measure camshaft end play. Refer to Specifications for proper clearance. If not within limits install a new thrust plate. 12. Each tappet reused must be installed in the same position from which it was removed. When camshaft is replaced, all of the tappets must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 1264 Camshaft: Service and Repair Shaft Prealignments NOTE: Before installing the distributor, the oil pump drive shaft must be aligned to number one cylinder. 1. Rotate crankshaft until No.1 cylinder is at top dead center on the firing stroke. 2. When in this position, the timing mark of vibration damper should be under "O" on the timing indicator. Position Of Oil Pump Shaft Slot 3. Install the shaft so that after the gear spirals into place, it will index with the oil pump shaft. The slot on top of oil pump shaft should be aligned towards the left front intake manifold attaching bolt hole. 4. Install distributor. After the distributor has been installed, its rotational position must be set using the SET SYNC mode of the DRB scan tool. Do not attempt to adjust ignition timing by rotating the distributor. It has no effect on ignition timing. Adjusting distributor position will effect fuel synchronization only. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Body Diameter 0.9035 - 0.9040 in Clearance in Block 0.0011 - 0.0024 in Dry Lash 0.06 - 0.210 in Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 1268 Lifter / Lash Adjuster: Testing and Inspection HYDRAULIC TAPPETS Before disassembling any part of the engine to correct tappet noise, check the oil pressure. If vehicle has no oil pressure gauge, install a reliable gauge at the pressure sending-unit. The pressure should be between 207-552 kPa (30-80 psi) at 3,000 RPM. Check the oil level after the engine reaches normal operating temperature. Allow 5 minutes to stabilize oil level, check dipstick. The oil level in the pan should never be above the FULL mark or below the ADD OIL mark on dipstick. Either of these two conditions could be responsible for noisy tappets. OIL LEVEL HIGH If oil level is above the FULL mark, it is possible for the connecting rods to dip into the oil. With the engine running, this condition could create foam in the oil pan. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily. LOW Low oil level may allow oil pump to take in air. When air is fed to the tappets, they lose length, which allows valves to seat noisily. Any leaks on intake side of oil pump through which air can be drawn will create the same tappet action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may be intermittent or constant, and usually more than one tappet will be noisy. When oil level and leaks have been corrected, operate the engine at fast idle. Run engine for a sufficient time to allow all of the air inside the tappets to be bled out. TAPPET NOISE DIAGNOSIS 1. To determine source of tappet noise, operate engine at idle with cylinder head covers removed. 2. Feel each valve spring or rocker arm to detect noisy tappet. The noisy tappet will cause the affected spring and/or rocker arm to vibrate or feel rough in operation. NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy tappets. If such is the case, noise may be dampened by applying side thrust on the valve spring. If noise is not appreciably reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm push rod sockets and push rod ends for wear. 3. Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by excessive leak-down around the unit plunger, or by the plunger partially sticking in the tappet body cylinder. The tappet should be replaced. A heavy click is caused by a tappet check valve not seating, or by foreign particles wedged between the plunger and the tappet body. This will cause the plunger to stick in the down position. This heavy click will be accompanied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, tappet assembly should be removed for inspection and cleaning. 4. The valve train generates a noise very much like a light tappet noise during normal operation. Care must be taken to ensure that tappets are making the noise. If more than one tappet seems to be noisy, it's probably not the tappets. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Removal and Installation Lifter / Lash Adjuster: Service and Repair Removal and Installation REMOVAL 1. Remove the air cleaner. 2. Remove cylinder head cover. 3. Remove rocker assembly and push rods. Identify push rods to ensure installation in original location. 4. Remove intake manifold. 5. Remove yoke retainer and aligning yokes. 6. Slide Hydraulic Tappet Remover/Installer Tool C-4129-A through opening in cylinder head and seat tool firmly in the head of tappet. 7. Pull tappet out of bore with a twisting motion. If all tappets are to be removed, identify tappets to ensure installation in original location. 8. If the tappet or bore in cylinder block is scored., scuffed, or shows signs of sticking, ream the bore to next oversize. Replace with oversize tappet. CAUTION: The plunger and tappet bodies are not interchangeable. The plunger and valve must always be fitted to the original body. It is advisable to work on one tappet at a time to avoid mixing of parts. Mixed parts are not compatible. DO NOT disassemble a tappet on a dirty work bench. NOTE: To disassemble and assemble tappets refer to Disassembly and Assembly procedures. INSTALLATION 1. Lubricate tappets. 2. Install tappets and push rods in their original positions. Ensure that the oil feed hole in the side of the tappet body faces up (away from the crankshaft). 3. Install aligning yokes with ARROW toward camshaft. 4. Install yoke retainer. Tighten the bolts to 23 Nm (200 inch lbs.) torque. 5. Install the intake manifold. 6. Install push rods in original positions. 7. Install rocker arms. 8. Install cylinder head covers. 9. Start and operate engine. Warm up to normal. operating temperature. CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Removal and Installation > Page 1271 Lifter / Lash Adjuster: Service and Repair Disassembly and Assembly CAUTION: The plunger and tappet bodies are not interchangeable. The plunger and valve must always be fitted to the original body. It is advisable to work on one tappet at a time to avoid mixing of parts. Mixed parts are not compatible. DO NOT disassemble a tappet on a dirty work bench. DISASSEMBLE Hydraulic Tappet Assembly 1. Pry out plunger retainer spring clip. 2. Clean varnish deposits from inside of tappet body above plunger cap. 3. Invert tappet body and remove plunger cap, plunger, check valve, check valve spring, check valve retainer and plunger spring. Check valve could be flat or ball. ASSEMBLE 1. Clean all tappet parts in a solvent that will remove all varnish and carbon. 2. Replace tappets that are unfit for further service with new assemblies. 3. If plunger shows signs of scoring or wear, install a new tappet assembly. If valve is pitted, or valve seat on end of plunger is prevented from seating, install a new tappet assembly. 4. Assemble tappets. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Specifications Push Rod: Specifications Push Rod Length 6.915 - 6.935 in Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Specifications > Page 1275 Push Rod: Service and Repair ROCKER ARMS AND PUSH RODS REMOVAL 1. Disconnect spark plug wires by pulling on the boot straight out in line with plug. 2. Remove cylinder head cover and gasket. Rocker Arms 3. Remove the rocker arm bolts and pivots. Place them on a bench in the same order as removed. 4. Remove the push rods and place them on a bench in the same order as removed. INSTALLATION 1. Rotate the crankshaft until the "V8" mark lines up with the TDC mark on the timing chain case cover. This mark is located 147° ATDC from the No. 1 firing position. 2. Install the push rods in the same order as removed. 3. Install rocker arm and pivot assemblies in the same order as removed. Tighten the rocker arm bolts to 28 Nm (21 ft. lbs.) torque. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes). 4. Install cylinder head cover. 5. Connect spark plug wires. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Bolts 21 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1279 Rocker Arm Assembly: Service and Repair ROCKER ARMS AND PUSH RODS REMOVAL 1. Disconnect spark plug wires by pulling on the boot straight out in line with plug. 2. Remove cylinder head cover and gasket. Rocker Arms 3. Remove the rocker arm bolts and pivots. Place them on a bench in the same order as removed. 4. Remove the push rods and place them on a bench in the same order as removed. INSTALLATION 1. Rotate the crankshaft until the "V8" mark lines up with the TDC mark on the timing chain case cover. This mark is located 147° ATDC from the No. 1 firing position. 2. Install the push rods in the same order as removed. 3. Install rocker arm and pivot assemblies in the same order as removed. Tighten the rocker arm bolts to 28 Nm (21 ft. lbs.) torque. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes). 4. Install cylinder head cover. 5. Connect spark plug wires. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Bearing Clearance .................................................................................................................................................... 0.013-0.056 mm (0.0005-0.0022 in) Side Clearance .................................................................................................................................... ........................... 0.152-0.356 mm (0.006-0.014 in) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Fitting Connecting Rod Bearings Connecting Rod Bearing: Service and Repair Fitting Connecting Rod Bearings Fit all rods on a bank until completed. DO NOT alternate from one bank to another, because connecting rods and pistons are not interchangeable from one bank to another. The bearing caps are not interchangeable and should be marked at removal to ensure correct assembly. Each bearing cap has a small V-groove across the parting face. When installing the lower bearing shell, make certain that the V-groove in the shell is in line with the V-groove in the cap. This provides lubrication of the cylinder wall in the opposite bank. The bearing shells must be installed so that the tangs are in the machined grooves in the rods and caps. Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 inch). Bearings are available in 0.025 mm (0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch) and 0.305 mm (0.012 inch) undersize. Install the bearings in pairs. DO NOT use a new bearing half with an old bearing half. DO NOT file the rods or bearing caps. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Fitting Connecting Rod Bearings > Page 1286 Connecting Rod Bearing: Service and Repair Connecting Rod Bearing Clearance CONNECTING ROD BEARING CLEARANCE Engine connecting rod bearing clearances can be determined by use of Plastigage, or equivalent. The following is the recommended procedures for the use of Plastigage: 1. Remove oil film from surface to be checked. Plastigage is soluble in oil. 2. Place a piece of Plastigage across the entire width of the bearing cap shell. Position the Plastigage approximately 6.35 mm (1/4 inch) off center and away from the oil holes. In addition, suspect areas can be checked by placing the Plastigage in the suspect area. 3. The crankshaft must be turned until the connecting rod to be checked starts moving toward the top of the engine. Only then should the rod cap with Plastigage in place be assembled. Tighten the 3.9L, and 5.2L rod cap nut to 61 Nm (45 ft. lbs.) torque. DO NOT rotate the crankshaft or the Plastigage may be smeared, giving inaccurate results. 4. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package. Plastigage generally comes in 2 scales (one scale is in inches and the other is a metric scale). Locate the band closest to the same width. This band shows the amount of clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken (refer to Engine Specifications). 5. Plastigage is available in a variety of clearance ranges. The 0.025-0.076 mm (0.001-0.003 inch) range is usually the most appropriate for checking engine bearing clearances. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts Connecting Rod: Specifications Connecting Rod Cap Bolts/Nuts Cap Bolts ............................................................................................................................................. ................................................. 61 Nm (45 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts > Page 1291 Connecting Rod: Specifications Connecting Rod Specifications Bearing Clearance ................................................................................................................................................. 0.013 0.056 mm (0.0005 - 0.0022 inch) Max. Allowable ............................................................................... .................................................................................................... 0.08 mm (0.003 inch) Piston Pin Bore Diameter .................................................................................................................................. 24.966 - 24.978 mm (0.9829 - 0.9834 inch) Side Clearance (Two Rods) ...................................................................................................................................... 0.152 - 0.356 mm (0.006 - 0.014 inch) Total Weight (Less Bearing) ......................................................................................................................................................... 758 grams (25.74 ounces) Cap Bolts ............................................................................................................................................. ..................................................... 61 Nm (45 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Checking Clearances Connecting Rod: Service and Repair Checking Clearances CONNECTING ROD BEARING CLEARANCE Engine connecting rod bearing clearances can be determined by use of Plastigage, or equivalent. The following is the recommended procedures for the use of Plastigage: 1. Remove oil film from surface to be checked. Plastigage is soluble in oil. 2. Place a piece of Plastigage across the entire width of the bearing cap shell. Position the Plastigage approximately 6.35 mm (1/4 inch) off center and away from the oil holes. In addition, suspect areas can be checked by placing the Plastigage in the suspect area. 3. The crankshaft must be turned until the connecting rod to be checked starts moving toward the top of the engine. Only then should the rod cap with Plastigage in place be assembled. Tighten the 3.9L, and 5.2L rod cap nut to 61 Nm (45 ft. lbs.) torque. DO NOT rotate the crankshaft or the Plastigage may be smeared, giving inaccurate results. 4. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package. Plastigage generally comes in 2 scales (one scale is in inches and the other is a metric scale). Locate the band closest to the same width. This band shows the amount of clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken (refer to Engine Specifications). 5. Plastigage is available in a variety of clearance ranges. The 0.025-0.076 mm (0.001-0.003 inch) range is usually the most appropriate for checking engine bearing clearances. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Checking Clearances > Page 1294 Connecting Rod: Service and Repair Fitting Connecting Rod Bearings Fit all rods on a bank until completed. DO NOT alternate from one bank to another, because connecting rods and pistons are not interchangeable from one bank to another. The bearing caps are not interchangeable and should be marked at removal to ensure correct assembly. Each bearing cap has a small V-groove across the parting face. When installing the lower bearing shell, make certain that the V-groove in the shell is in line with the V-groove in the cap. This provides lubrication of the cylinder wall in the opposite bank. The bearing shells must be installed so that the tangs are in the machined grooves in the rods and caps. Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 inch). Bearings are available in 0.025 mm (0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch) and 0.305 mm (0.012 inch) undersize. Install the bearings in pairs. DO NOT use a new bearing half with an old bearing half. DO NOT file the rods or bearing caps. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Rebuild Specifications Crankshaft Main Bearing: Specifications Rebuild Specifications Main Bearing Journals Diameter .............................................................................................................................................................. 71.361-71.387 mm (2.8095-2.8105 in.) Out-of-Round (Max) .............................................................. ........................................................................................................ 0.0254 mm (0.001 in.) Taper (Max) ................................................................................................................................................... ................................ 0.0254 mm (0.001 in.) Diametrical Clearance No. 1 .................................................................................................................................................... .................... 0.013-0.038 mm (0.0005-0.0015 in.) Service Limit (No. 1) ............................................ ....................................................................................................................... 0.0381 mm (0.0015 in.) No. 2,3,4,5 ........................................................................................................................................... .................... 0.013-0.051 mm (0.0005-0.0002 in.) Service Limit (Nos. 2,3,4,5) .......................................................................................................................................................... 0.064 mm (0.0025 in.) End Play .............................................................................................................................................. ........................ 0.051-0.178 mm (0.002-0.178 in.) Service Limit ........................................................ ............................................................................................................................ 0.254 mm (0.010 in.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Rebuild Specifications > Page 1299 Crankshaft Main Bearing: Specifications Torque Specifications Cap Bolts ............................................................................................................................................. .................................................. 115 Nm (85 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1300 Crankshaft Main Bearing: Service and Repair FITTING CRANKSHAFT MAIN BEARINGS Main Bearing Identification Bearing caps are not interchangeable and should be marked at removal to ensure correct assembly. Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves of No.2 and 4 are interchangeable. Upper and lower No.3 bearing halves are flanged to carry the crankshaft thrust loads. They are NOT interchangeable with any other bearing halves in the engine. Bearing shells are available in standard and the following undersizes: 0.25 mm (0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch) and 0.305 mm (0.012 inch). Never install an undersize bearing that will reduce clearance below specifications. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Dimensions Crankshaft: Specifications Dimensions CONNECT ROD JOURNAL: Diameter ............................................................................................................................................................ 53.950 - 53.975 mm (2.124 - 2.125 inch) Out-of-Round (Max.) .......................................................... ......................................................................................................... 0.0254 mm (0.001 inch) Taper (Max.) .................................................................................................................................................. .............................. 0.0254 mm (0.001 inch) DIAMETRICAL CLEARANCE: No. 1 .................................................................................................................................................... .............. 0.013 - 0.038 mm (0.0005 - 0.0015 inch) Max. Allowable No. 1 .......................................... ..................................................................................................................... 0.0381 mm (0.0015 inch) Nos. 2,3,4 and 5 ................................................................................................................................................ 0.013 0.051 mm (0.0005 - 0.0020 inch) Max. Allowable (Nos. 2,3,4 and 5) .............................................................................................................................................. 0.064 mm (0.0025 inch) END PLAY: Standard .............................................................................................................................................. .................. 0.051 - 0.178 mm (0.002 - 0.007 inch) Max. Allowable .................................................... ......................................................................................................................... 0.254 mm (0.010 inch) MAIN BEARING JOURNALS: Diameter ........................................................................................................................................................ 71.361 - 71.387 mm (2.8095 - 2.8105 inch) Out-of-Round (Max.) ...................................................... ............................................................................................................. 0.0254 mm (0.001 inch) Taper (Max.) ........................................................................................................................................ ........................................ 0.0254 mm (0.001 inch) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Dimensions > Page 1305 Crankshaft: Specifications Crankshaft Main Bearing Caps 85 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation Crankshaft: Service and Repair Removal and Installation Location Of Crankshaft Identification A crankshaft which has undersize journals will be stamped with 1/4 inch letters on the milled flat on the No.3 crankshaft counterweight. FOR EXAMPLE: R2 stamped on the No.3 crankshaft counterweight indicates that the No.2 rod journal is 0.025 mm (0.001 in) undersize. M4 indicates that the No.4 main journal is 0.025 mm (0.001 in) undersize. R3 M2 indicates that the No.3 rod journal and the No.2 main journal are 0.025 mm (0.001 in) undersize. When a crankshaft is replaced, all main and connecting rod bearings should be replaced with new bearings. Therefore, selective fitting of the bearings is not required when a crankshaft and bearings are replaced. REMOVAL 1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Identify bearing caps before removal. Remove bearing caps and bearings one at a time. 4. Lift the crankshaft out of the block. 5. Remove and discard the crankshaft rear oil seals. 6. Remove and discard the front crankshaft oil seal. CLEANING Clean Loctite 518 residue and sealant from the cylinder block and rear cap mating surface. Do this before applying the Loctite drop and the installation of rear cap. INSTALLATION 1. Lightly oil the new upper seal lips with engine oil. 2. Install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine. 3. Position the crankshaft into the cylinder block. 4. Lightly oil the new lower seal lips with engine oil. 5. Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine. Sealant Application To Bearing Cap 6. Apply 5 mm (0.20 in) drop of Loctite 518, or equivalent, on each side of the rear main bearing cap. DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1308 7. To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. 8. Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten to 115 Nm (85 ft. lbs.) torque. 9. Install oil pump. 10. Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing (refer to Oil Pan Replacement). 11. Install new front crankshaft oil seal. 12. Immediately install the oil pan. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1309 Crankshaft: Service and Repair Cleaning and Inspection INSPECTION OF JOURNALS The crankshaft connecting rod and main journals should be checked for excessive wear, taper and scoring. The maximum taper or out-of-round on any, crankshaft journal is 0.025 mm (0.001 inch). Journal grinding should not exceed 0.305 mm (0.012 inch) under the standard journal diameter. DO NOT grind thrust faces of No.3 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and. clean out all oil passages. CAUTION: After any journal grind, it is important that the final paper or cloth polish be in the same direction as the engine rotates. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1310 Crankshaft: Service and Repair Service Procedures Location Of Crankshaft Identification A crankshaft which has undersize journals will be stamped with 1/4 inch letters on the milled flat on the No.3 crankshaft counterweight. FOR EXAMPLE: R2 stamped on the No.3 crankshaft counterweight indicates that the No.2 rod journal is 0.025 mm (0.001 in) undersize. M4 indicates that the No.4 main journal is 0.025 mm (0.001 in) undersize. R3 M2 indicates that the No.3 rod journal and the No.2 main journal are 0.025 mm (0.001 in) undersize. When a crankshaft is replaced, all main and connecting rod bearings should be replaced with new bearings. Therefore, selective fitting of the bearings is not required when a crankshaft and bearings are replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation Engine Block Heater: Description and Operation BLOCK HEATER An optional engine block heater is available for all models. The heater is equipped with a power cord that is located behind the grille. The cord is attached to an engine compartment component with tie-straps. The heater warms the engine providing easier engine starting and faster warm-up in low temperatures. The heater is mounted in a core hole of the engine cylinder block (in place of freeze plug) with the heating element immersed in engine coolant. The power cord is located behind the radiator grille. Connect the power cord to a grounded, 110-120 volt AC electrical outlet with a grounded, three wire extension cord. WARNING: DO NOT OPERATE ENGINE UNLESS BLOCK HEATER CORD HAS BEEN DISCONNECTED FROM POWER SOURCE AND SECURED IN PLACE. THE POWER CORD MUST BE SECURED IN ITS RETAINING CLIPS AND ROUTED AWAY FROM EXHAUST MANIFOLDS AND MOVING PARTS. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1314 Engine Block Heater: Service and Repair REMOVAL 1. Disconnect negative battery cable at battery. WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAIN PLUG WITH SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR. 2. Drain coolant from radiator and cylinder block. Engine Block Heater 3. Remove power cord from block heater. 4. Loosen screw at center of block heater. Remove block heater assembly. INSTALLATION 1. Thoroughly clean cylinder block core hole and block heater seat. 2. Insert block heater assembly with element loop pointing down. 3. With block heater fully seated, tighten center screw to 2 Nm (17 inch lbs.) torque. 4. Fill cooling system with recommended coolant. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Specifications Expansion/Freeze Plug: Specifications Pipe Plugs All ...................................................................................................................................... ................................................... 34 Nm (25 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Specifications > Page 1318 Expansion/Freeze Plug: Service and Repair Location Of Cup Plugs In Oil Galleries Engine core plugs have been pressed into the oil galleries behind the camshaft thrust plate . This will reduce internal leakage and help maintain higher oil pressure at idle. REMOVAL Core Hole Plug Removal 1. Using a blunt tool such as a drift or a screwdriver and a hammer, strike the bottom edge of the cup plug. 2. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug. CLEANING Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Make certain the new plug is cleaned of all oil or grease. INSTALLATION 1. Coat edges of plug and core hole with Mopar Gasket Maker, or equivalent. CAUTION: DO NOT drive cup plug into the casting as restricted coolant flow can result and cause serious engine problems. 2. Using proper plug drive, drive cup plug into hole. The sharp edge of the plug should be at least 0.50 mm (0.020 inch) inside the lead-in chamfer. 3. It is not necessary to wait for curing of the sealant. The cooling system can be filled and the vehicle placed in service immediately. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Crankshaft Pulley Harmonic Balancer - Crankshaft Pulley: Specifications Chrankshaft Pulley Chrankshaft Pulley Torque Specifications 24 Nm (210 in.lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Crankshaft Pulley > Page 1323 Harmonic Balancer - Crankshaft Pulley: Specifications Vibration Damper Bolt 135 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1324 Harmonic Balancer - Crankshaft Pulley: Service and Repair VIBRATION DAMPER REMOVAL 1. Disconnect the negative cable from the battery. 2. Remove fan shroud retainer bolts and set shroud back over engine. 3. Remove the cooling system fan. 4. Remove the serpentine belt. 5. Remove the vibration damper pulley. 6. Remove vibration damper bolt and washer from end of crankshaft. Vibration Damper Assembly 7. Install bar and screw from Puller Tool Set C-3688. Install 2 bolts with washers through the puller tool and into the vibration damper. 8. Pull vibration damper off of the crankshaft. INSTALLATION 1. Position the vibration damper onto the crankshaft. Installing Vibration Damper 2. Place installing tool, part of Puller Tool Set C-3688 in position and press the vibration damper onto the crankshaft. 3. Install the crankshaft bolt and washer. Tighten the bolt to 183 Nm (135 ft. lbs.) torque. 4. Install the crankshaft pulley. Tighten the pulley bolts to 23 Nm (200 inch lbs.) torque. 5. Install the serpentine belt. 6. Install the cooling system fan. Tighten the bolts to 23 Nm (17 ft. lbs.) torque. 7. Position the fan shroud and install the bolts. Tighten the retainer bolts to 11 Nm (95 inch lbs.) torque. 8. Connect the negative cable to the battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Clearance at Top of Skirt 0.0005 - 0.0015 in Land Clearance (Diam.) 0.020 - 0.026 in Ring Groove Depth (#1&2) 0.187 - 0.193 in Ring Groove Depth (#3) 0.157 - 0.164 in Piston Length 3.19 inch Weight 20.53 - 20.67 oz (US) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1328 Piston: Description and Operation PISTONS The pistons are elliptically turned so that the diameter at the pin boss is less than its diameter across the thrust face. This allows for expansion under normal operating conditions. Under operating temperatures, expansion forces the pin bosses away from each other, causing the piston to assume a more nearly round shape. All pistons are machined to the same weight, regardless of size, to maintain piston balance. The piston pin rotates in the piston only and is retained by the press interference fit of the piston pin in the connecting rod. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation Piston: Service and Repair Removal and Installation REMOVAL 1. Remove the engine from the vehicle. 2. Remove the cylinder head. 3. Remove the oil pan. 4. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. 5. Be sure the connecting rod and connecting rod cap are identified with the cylinder number. Remove connecting rod cap. Install connecting rod bolt guide set on connecting rod bolts. 6. Pistons and connecting rods must be removed from top of cylinder block. When removing the assemblies from the engine, rotate crankshaft so that the connecting rod is centered in cylinder bore and at BDC. Be careful not to nick crankshaft journals. 7. After removal, install bearing cap on the mating rod. INSPECTION Piston Measurements Check the crankshaft connecting rod journal for excessive wear, taper and scoring. Check the cylinder block bore for out-of-round, taper, scoring and scuffing. Check the pistons for taper and elliptical shape before they are fitted into the cylinder bore. NOTE: To fit pistons and rings refer to Fitting Pistons and/or Fitting Piston Rings. INSTALLATION 1. Be sure that compression ring gaps are staggered so that neither is in-line with oil ring rail gap. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1331 Proper Ring Installation 2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located properly. 3. Immerse the piston head and rings in clean engine oil. Slide Piston Ring Compressor Tool C-385 over the piston and tighten with the special wrench (part of Tool C-385). Be sure position of rings does not change during this operation. 4. Install connecting rod bolt protectors on rod bolts, the long protector should be installed on the numbered side of the connecting rod. 5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Be sure connecting rod and cylinder bore number are the same. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. 6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on crankshaft journal. 7. The notch or groove on top of piston must be pointing toward front of engine. The larger chamfer of the connecting rod bore must be installed toward crankshaft journal fillet. 8. Install rod caps. Be sure connecting rod, connecting rod cap and cylinder bore number are the same. Install nuts on cleaned and oiled rod bolts and tighten nuts to 61 Nm (45 ft. lbs.) torque. 9. Install the oil pan. 10. Install the cylinder head. 11. Install the engine into the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1332 Piston: Service and Repair Fitting Pistons Piston Measurements Piston and cylinder wall must be clean and dry Specified clearance between the piston and the cylinder wall is 0.013-0.038 mm (0.0005-0.0015 inch) at 21°C (70°F). Piston diameter should be measured at the top of skirt, 90° to piston pin axis location A. Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line. Pistons and cylinder bores should be measured at normal room temperature, 21°C (70°F). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Clearance in Piston 0.00023 - 0.00074 in Diameter 0.9845 - 0.9848 in End Play NONE Length 2.67 - 3.69 in Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Ring Gap Compression Ring (Top) 0.012 - 0.022 in Compression Ring (2nd) 0..022 - 0.031 in Oil Ring (Steel Rails) 0.015 - 0.055 in Ring Side Clearance Compression Rings 0.0016 - 0.0033 in Oil Ring (Steel Rails) 0.002 - 0.008 in Ring Width Compression Rings 0.060 - 0.061 in Oil Ring (Steel Rails) - Max. 0.018 - 0.019 in Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1339 Piston Ring: Service and Repair 1. Measurement of end gaps: a. Measure piston ring gap 2 inches from bottom of cylinder bore. An inverted piston can be used to push the rings down to ensure positioning rings squarely in the cylinder bore before measuring. b. Insert feeler gauge in the gap. The top compression ring gap should be between 0.254-0.508 mm (0.010-0.020 inch). The second compression ring gap should be between 0.508-0.762 mm (0.020-0.030 inch). The oil ring gap should be 0.254-1.270 mm (0.010-0.050 inch). c. Rings with insufficient end gap may be properly filed to the correct dimension. Rings with excess gaps should not be used. 2. Install rings and confirm ring side clearance: a. Install oil rings being careful not to nick or scratch the piston. Install the oil control rings according to instructions in the package. It is not necessary to use a tool to install the upper and lower rails. Insert oil rail spacer first, then side rails. Top Compression Ring Identification (Typical) Compression Ring Chamfer Location (Typical) b. Install the second compression rings using Installation Tool C-4184. The compression rings must be installed with the identification mark face up (toward top of piston) and chamfer facing down. An identification mark on the ring is a drill point, a stamped letter "O", an oval depression or the word TOP. Second Compression Ring Identification (Typical) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1340 Proper Ring Installation c. Using a ring installer, install the top compression ring with the chamfer facing up. An identification mark on the ring is a drill point, a stamped letter "O", an oval depression or the word TOP facing up. d. Measure side clearance between piston ring and ring land. Clearance should be 0.074-0.097 mm (0.0029-0.0038 inch) for the compression rings. The steel rail oil ring should be free in groove, but should not exceed 0.246 mm (0.0097 inch) side clearance. e. Pistons with insufficient or excessive side clearance should be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair NOTE: Use following procedure if fuel rail is or is not equipped with fuel pressure test port. 1. Remove fuel fill cap. 2. The fuel filler tube contains a spring-loaded flap (door) located below fuel fill cap. The flap is used as a secondary way of sealing fuel tank if fuel fill cap has not been properly tightened. It is part of EVAP monitor system when vehicle is equipped with a Leak Detection Pump (LDP). The vehicle may be equipped with flap installed into fuel filler tube even though vehicle is not equipped with LDP and EVAP monitor system. Place a nonmetallic object into fuel fill tube and press on flap to relieve any tank pressure. 3. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 7. Unplug connector from any injector. 8. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 9. Connect other end of jumper wire to positive side of battery. 10. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 11. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 12. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 13. Disconnect quick-connect fitting at fuel rail. 14. Return fuel pump relay to PDC. 15. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Bolts 21 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1351 Rocker Arm Assembly: Service and Repair ROCKER ARMS AND PUSH RODS REMOVAL 1. Disconnect spark plug wires by pulling on the boot straight out in line with plug. 2. Remove cylinder head cover and gasket. Rocker Arms 3. Remove the rocker arm bolts and pivots. Place them on a bench in the same order as removed. 4. Remove the push rods and place them on a bench in the same order as removed. INSTALLATION 1. Rotate the crankshaft until the "V8" mark lines up with the TDC mark on the timing chain case cover. This mark is located 147° ATDC from the No. 1 firing position. 2. Install the push rods in the same order as removed. 3. Install rocker arm and pivot assemblies in the same order as removed. Tighten the rocker arm bolts to 28 Nm (21 ft. lbs.) torque. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes). 4. Install cylinder head cover. 5. Connect spark plug wires. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Removal and Installation Valve Cover: Service and Repair Removal and Installation CYLINDER HEAD COVER Cylinder Head Cover Gasket NOTE: A steel backed silicon gasket is used with the cylinder head cover. This gasket can be used again. REMOVAL 1. Disconnect the negative cable from the battery. 2. Disconnect closed ventilation system and evaporation control system from cylinder head cover. 3. Remove cylinder head cover and gasket. The gasket may be used again. CLEANING Clean cylinder head cover gasket surface. Clean head rail, if necessary. INSTALLATION 1. The cylinder head cover gasket can. be used again. Install the gasket onto the head rail.. 2. Position the cylinder head cover onto the gasket. Tighten the bolts to 11 Nm (95 inch lbs.) torque. 3. Install closed crankcase ventilation system and evaporation control system. 4. Connect the negative cable to the battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Removal and Installation > Page 1356 Valve Cover: Service and Repair Cleaning and Inspection CYLINDER HEAD COVER A steel-backed silicone gasket is used with the cylinder head cover. This gasket is reuseable. Cylinder Head Cover Gasket A steel backed silicon gasket is used with the cylinder head cover. This gasket can be used again. CLEANING Clean cylinder head cover gasket surface. Clean head rail, if necessary. INSPECTION Inspect cover for distortion and straighten, if necessary. Check the gasket for use in head cover installation. If damaged, use a new gasket. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Guide Bore 0.313 - 0.314 in Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Angle 44.25 - 44.75 deg Runout (Max) 0.003 in Width (Finish) - Intake 0.040 - 0.060 in Width (Finish) - Exhaust 0.060 - 0.080 in Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications > Page 1363 Valve Seat: Service and Repair For information regarding valve seat regrinding, please refer to Valve, Intake/Exhaust; Service and Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Free Lenght 1.967 in Spring Tension (valve closed) 85 lbf at 1.64 in Spring Tension (valve open) 200 lbf at 1.212 in Installed Height 1.64 in Number of Coils 6.8 Wire Diameter 0.177 in Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off Valve Spring: Service and Repair Cylinder Head Off Refer to Valves, Intake/Exhaust, Service and Repair for procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off > Page 1369 Valve Spring: Service and Repair Cylinder Head On 1. Remove the air cleaner. 2. Remove cylinder head covers and spark plugs. 3. Remove coil wire from distributor and secure to good ground to prevent engine from starting. 4. Using suitable socket and flex handle at crankshaft retaining bolt, turn engine so the No.1 piston is at TDC on the compression stroke. 5. Remove rocker arms. 6. With air hose attached to an adapter installed in No.1 spark plug hole, apply 620-689 kPa (90-100 psi) air pressure. 7. Using Valve Spring Compressor Tool MD-998772A with adaptor 6716A, compress valve spring and remove retainer valve locks and valve spring. 8. Install seals on the exhaust valve stem and position down against valve guides. 9. The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as a guide. DO NOT force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. 10. Follow the same procedure on the remaining 7 cylinders using the firing sequence 1-8-4-3-6-5-7-2. Make sure piston in cylinder is at TDC on the valve spring that is being removed. 11. Remove adapter from the No.1 spark plug hole. 12. Install rocker arms. 13. Install covers and coil wire to distributor. 14. Install air cleaner. 15. Road test vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Face Angle 43.25 - 43.75 deg Head Diameter - Intake 1.88 in Head Diameter - Exhaust 1.617 in Length (Overall) - Intake 4.969 - 4.994 in Lenght (Overall) - Exhaust 4.978 - 5.012 in Stem Diameter - Intake 0.372 - 0.373 in Stem Diameter - Exhaust 0.371 - 0.372 in Stem to Guide Clearance - Intake 0.001 - 0.003 in Stem to Guide Clearance - Exhaust 0.002 - 0.004 in Service Limit ( Rocking Methood) 0.017 in Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1373 Valve: Description and Operation VALVES AND VALVE SPRINGS The valves are arranged in-line and inclined 18°. The rocker pivot support and the valve guides are cast integral with the heads. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation Valve: Service and Repair Removal and Installation VALVES AND VALVE SPRINGS-HEAD REMOVED REMOVAL 1. Remove the cylinder head. 2. Compress valve springs using Valve Spring Compressor Tool MD- 998772A and adaptor 6716A. 3. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. 4. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original location. VALVE CLEANING Clean valves thoroughly. Discard burned, warped and cracked valves. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. INSTALLATION 1. Coat valve stems with lubrication oil and insert them in cylinder head. 2. If valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head. 3. Install new seals on all valve guides. Install valve springs and valve retainers. 4. Compress valve springs with Valve Spring Compressor Tool MD-998772A and adaptor 6716A, install locks and release tool. If valves and/or seats are ground, measure the installed height of springs. Make sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer. If spacers are installed, measure from the top of spacer. If height is greater than 42.86 mm (1-11/16 inches), install a 1.587 mm (1/16 inch) spacer in head counterbore. This should bring spring height back to normal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1376 Valve: Service and Repair Valve Service VALVE CLEANING Clean valves thoroughly Discard burned, warped and cracked valves. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. VALVE INSPECTION Measure valve stems for wear. If wear exceeds 0.051 mm (0.002 inch), replace the valve. REFACING VALVES AND VALVE SEATS Valve Face And Seat Angles The intake and exhaust valves have a 43-1/4° to 43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle. VALVES Intake And Exhaust Valves Inspect the remaining margin after the valves are refaced. Valves with less than 1.190 mm (0.047 inch) margin should be discarded. VALVE GUIDES Measure valve stem guide clearance as follows: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1377 Positioning Valve With Tool C-3973 1. Install Valve Guide Sleeve Tool C-3973 over valve stem and install valve. The special sleeve places the valve at the correct height for checking with a dial indicator. Measuring Valve Guide Wear 2. Attach Dial Indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured. Reamer Sizes 3. Move valve to and from the indicator. The total dial indicator reading should not exceed 0.432 mm (0.017 inch). Ream the guides for valves with over-size stems if dial indicator reading is excessive or if the stems are scuffed or scored. Service valves with oversize stems are available. Slowly turn reamer by hand and clean guide thoroughly before installing new valve. Ream the valve guides from standard to 0.381 mm (0.015 inch). Use a 2 step procedure so the valve guides are reamed true in relation to the valve seat: ^ Step 1-Ream to 0.0763 mm (0.003 inch). ^ Step 2-Ream to 0.381 mm (0.015 inch). VALVE SEATS Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1378 Refacing Valve Seats CAUTION: DO NOT un-shroud valves during valve seat refacing. 1. When refacing valve seats, it is important that, the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained. 2. Measure the concentricity of valve seat using a. dial indicator. Total runout should not exceed 0.051 mm (0.002 inch) total indicator reading. 3. Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light, pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to the top edge of valve face, lower valve seat, with a 15° stone. If the blue is transferred to bottom edge of valve face raise valve seat with a 60° stone. 4. When seat is properly positioned the width of intake seats should be 1.016-1.524 mm (0.040-0.060 inch). The width of the exhaust seats should be 1.524-2.032 mm (0.060-0.080 inch). VALVE SPRING INSPECTION Testing Valve Spring For Compression Length Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested. As an example the compression length of the spring to be tested is 1-5/16 inch. Turn table of Universal Valve Spring Tester Tool until surface is in line with the 1-5/16 inch mark on the threaded stud. Be sure the zero mark is to the front. Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by 2. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to specifications to obtain specified height and allowable tensions. Discard the springs that do not meet specifications. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams Belt Routing-All Engines Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1383 Drive Belt: Description and Operation ACCESSORY DRIVE BELT/TENSION The accessory drive components are operated by a single, crankshaft driven, serpentine drive belt. An automatic belt tensioner is used to maintain correct belt tension at all times. Correct accessory drive belt tension is required to be sure of optimum performance of belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate and greatly reduced belt life. It is not necessary to adjust belt tension on any engine. All engines are equipped with an automatic belt tensioner. The tensioner maintains correct belt tension at all times. Due to use of this belt tensioner, do not attempt to use a belt tension gauge on any engine. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1384 Drive Belt: Testing and Inspection VISUAL DIAGNOSIS Belt Ware Patterns When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to the Accessory Drive Belt Diagnosis charts for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1385 ACCESSORY DRIVE BELT DIAGNOSIS CHART Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1386 Drive Belt: Service and Repair ACCESSORY DRIVE BELT The accessory drive components are operated by a single, crankshaft driven, serpentine drive belt. An automatic belt tensioner is used to maintain correct belt tension at all times. CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner. REMOVAL Belt Tensioner-Typical 1. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 2. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from idler pulley first. 4. Remove belt from vehicle. INSTALLATION Belt Routing-All Engines CAUTION: When installing "serpentine" accessory drive belt, belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. The correct belt with correct length must be used. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1387 The following belt routing schematics are published from the latest information available at the time of publication. If anything differs between these schematics and the Belt Routing Label, use the schematics on Belt Routing Label. This label is located in the engine compartment. 1. Position drive belt over all pulleys except idler pulley. This pulley is located between generator and A/C compressor. 2. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 3. Rotate socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly seated on all pulleys. Tensioner Indexing Marks 4. Check belt indexing marks. 5. The tensioner is equipped with an indexing arrow on back of tensioner and an indexing mark on tensioner housing. If a new belt is being installed, arrow must be within approximately 3 mm (1/8 in.) of indexing mark (Point B). Belt is considered new if it has been used 15 minutes or less. If this specification cannot be met, check for: ^ The wrong belt being installed (incorrect length/ width) ^ Worn bearings on an engine accessory (A/C compressor, power steering pump, water pump, idler pulley or generator) ^ A pulley on an engine accessory being loose ^ Misalignment of an engine accessory ^ Belt incorrectly routed. A used belt should be replaced if tensioner indexing arrow has moved beyond point A. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Belt Tensioner Pulley 45 ft.lb Belt Tensioner to Bracket 50 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 1391 Drive Belt Tensioner: Description and Operation AUTOMATIC BELT TENSIONER Belt Tensioner-Typical Drive belts on all engines are equipped with a spring loaded automatic belt tensioner. This belt tensioner will be used with all belt configurations, such as with or without power steering or air conditioning. CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 1392 Drive Belt Tensioner: Service and Repair REMOVAL 1. Remove accessory drive belt. 2. Disconnect wiring and secondary cable from ignition coil. 3. Remove ignition coil from coil mounting bracket (two bolts). Do not remove coil mounting bracket from cylinder head. 4. Remove tensioner assembly from mounting bracket (one nut). WARNING: BECAUSE OF HIGH SPRING PRESSURE, DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY (EXCEPT FOR PULLEY). 5. Remove pulley bolt. Remove pulley from tensioner. INSTALLATION 1. Install pulley and pulley bolt to tensioner. Tighten bolt to 61 Nm (45 ft. lbs.). 2. Install tensioner assembly to mounting bracket. An indexing tab is located on back of tensioner. Align this tab to slot in mounting bracket. Tighten nut to 67 Nm (50 ft. lbs.) torque. 3. Connect all wiring to ignition coil. 4. Install coil to coil bracket. If nuts and bolts are used to secure coil to coil bracket, tighten to 11 Nm (100 inch lbs.) torque. If coil mounting bracket has been tapped for coil mounting bolts, tighten bolts to 5 Nm (50 inch lbs.) torque. CAUTION: To prevent damage to coil case, coil mounting bolts must be torqued. 5. Install drive belt. Tensioner Indexing Marks 6. Check belt indexing marks. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications Engine Mount: Specifications Insulator Bracket to Block (Front) 30 ft.lb Insulator to Bracket/Crossmember (Front) 75 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications > Page 1396 Engine Mount: Service and Repair REMOVAL 1. Raise hood and position fan to assure clearance for radiator top tank and hose. 2. Disconnect the negative cable from the battery. CAUTION: DO NOT lift the engine by the intake manifold. 3. Install engine lifting fixture. 4. Raise vehicle on hoist. Front Mounts-Right Side Front Mounts-Left Side 5. Remove nuts from brackets and insulators. 6. Raise engine with support fixture only far enough to remove insulators. INSTALLATION 1. If removed, install the engine mounting bracket to the cylinder block. Tighten the bolts to 88 Nm (65 ft. lbs.) torque. 2. With engine raised SLIGHTLY, install insulators. 3. Lower engine with support fixture while guiding insulator studs into attaching holes in crossmember and brackets. 4. Tighten the attaching nuts to 102 Nm (75 ft. lbs.) torque. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications > Page 1397 5. Lower the vehicle. 6. Remove engine support fixture. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications Idler Pully 45 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE @ Curb Idle (Min.*) .............................................................................................................................. ................................................... 41.4 kPa (6 psi) @ 3000 rpm .......................................................... ................................................................................................................... 207 - 552 kPa (30 - 80 psi) Bypass Valve Setting .................................................................................................................... ............................................... 62 - 103 kPa (9 - 15 psi) Switch Actuating pressure ......................................................................................................................................................... 34.5 - 48.3 kPa (5 - 7 psi) CAUTION: If oil pressure is zero at curb idle, DO NOT RUN ENGINE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Description and Operation Engine Oil Dip Stick - Dip Stick Tube: Description and Operation OIL LEVEL INDICATOR (DIPSTICK) Engine Oil Dipstick Location The engine oil level indicator is located at the right front of the engine, left of the generator. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Oil Drain Plug 25 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Without Filter Change .......................................................................................................................... ............................................................. 4.2L (4.5 Qt) Capacity shown is without filter. When replacing filter, additional oil may be needed Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1415 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................... SH or SH/CD or Above Above 0°F (-18°C).............................................. ........................................................................................................................................................ 10W-30 Below 32°F (0°C).................................................................................................................... ..................................................................................... 5W-30 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1416 Engine Oil: Service Precautions WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1417 Engine Oil: Description and Operation ENGINE OIL SPECIFICATION. CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. API SERVICE GRADE CERTIFIED Engine Oil Container Standard Notations Use an engine oil that is API Service Grade Certified. Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans. SAE VISCOSITY Temperature/Engine Oil Viscosity An SAE viscosity grade is used to specify the viscosity of engine oil. SAE 1OW-30 specifies a multiple viscosity engine oil. When choosing an engine oil, consider the range of temperatures the vehicle will be operated in before the next oil change. Select an engine oil that is best suited to your area's particular ambient temperature range and variation. ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CON-SERVING is located on the label of an engine oil container. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1418 Engine Oil: Testing and Inspection CRANKCASE OIL LEVEL INSPECTION CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable oil level is in the SAFE RANGE on the engine oil dipstick. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately ten minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the SAFE RANGE area on the dipstick. ENGINE OIL PRESSURE 1. Remove oil pressure sending unit. 2. Install Oil Pressure Line and Gauge Tool C-3292. Start engine and record pressure. Refer to Oil Pressure in Engine Specifications for the proper pressures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1419 Engine Oil: Service and Repair ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in the Maintenance Schedule. TO CHANGE ENGINE OIL Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and amount of engine oil described. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter Connector 50 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 1423 Oil Filter: Description and Operation FILTER SPECIFICATION All Dodge Ram engines are equipped with a high quality full-flow, disposable type oil filter. Chrysler Corporation recommends a Mopar or equivalent oil filter be used. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 1424 Oil Filter: Service and Repair OIL FILTER REMOVAL 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter. Oil Filter Removal-Typical 3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss. 4. When filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove filter from vehicle. Oil Filter Sealing Surface-Typical 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. OIL FILTER INSTALLATION 1. Lightly lubricate oil filter gasket with engine oil or chassis grease. 2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, hand tighten filter one full turn, do not over tighten. 3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts 215 in.lb Oil Pan Drain Plugs 25 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1428 Oil Pan: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Remove engine oil dipstick. 3. Remove air cleaner inlet duct. 4. Unbolt the engine controller from the cowl and secure out of the way. DO NOT DISCONNECT. 5. Remove upper cooling fan shroud fasteners. 6. Remove engine cover. 7. Raise vehicle on hoist. 8. Drain engine oil. 9. Remove transmission oil cooler lines from the oil pan mounting clip. 10. Remove engine to transmission. support braces. 11. Remove starter motor. 12. Remove transmission inspection cover. Engine Mount Insulator-Right Side Engine Mount Insulator-Left Side 13. Remove left and right engine mount insulator nuts. 14. Remove the oil pan fasteners. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1429 15. Remove the oil pan from the vehicle. Note: The crankshaft may have to be rotated for the oil pan to clear the #1&2 journal counterweight on removal. CLEANING 1. Clean the cylinder block and oil pan mating surfaces. 2. Trim or remove excess sealant film in the rear main cap oil pan gasket groove. DO NOT remove the sealant inside the rear main cap slots. 3. If present, trim excess sealant from inside the engine. Clean oil pan in solvent and wipe dry with a clean cloth. Clean oil screen and pipe thoroughly in clean solvent. Inspect condition of the screen. INSPECTION 1. Inspect the oil pan drain plug and hole for, stripped or damaged threads. Repair as necessary. 2. Inspect oil pan mounting flange for bends or distortion. Straighten flange, if necessary. INSTALLATION Fabrication Of Alignment Dowels 1. Fabricate four alignment dowels from 5/16 x 1 1/2 inch bolts. Cut the head off the bolts and cut a slot into the top of the dowel. This will allow easier installation and removal with a screwdriver. Position Of Dowels In Cylinder Block 2. Install the dowels in the cylinder block. 3. Apply a small amount of Mopar Silicone Rubber Adhesive Sealant, or equivalent in the comer of the cap and the cylinder block. 4. Slide the one piece gasket over the dowels and onto the block. 5. Position the oil pan over the dowels and onto the gasket. 6. Install the oil pan bolts. Tighten the bolts to 24 Nm (215 inch lbs.). 7. Remove the dowels. Install and tighten the remaining pan bolts to 24 Nm (215 inch lbs.). 8. Install and tighten the oil pan drain plug to 34 Nm (25 ft. lbs.). 9. Lower the engine while aligning the engine mount insulators with the brackets. 10. Install the mount insulator nuts and tighten to 102 Nm (75 ft. lbs.). 11. Install the transmission inspection cover. 12. Install the starter motor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1430 13. Install the engine to transmission support brackets. 14. Install the transmission oil cooler lines into the mounting clips. 15. Lower the vehicle. 16. Install the upper cooling fan shroud. 17. Fasten the controller to the cowl. 18. Install the air cleaner inlet duct. 19. Install the engine oil dipstick. 20. Fill the crankcase with engine oil. 21. Connect the battery negative cable. 22. Start engine and check for leaks. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation SYSTEM OPERATION The oil pressure gauge gives an indication of the engine oil pressure. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon engine oil pressure messages received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the engine oil pressure sensor and internal programming to decide what engine oil pressure messages are required. The PCM then sends the proper messages to the instrument cluster on the CCD data bus. If the PCM messages indicate that oil pressure is too low, the instrument cluster circuitry moves the gauge needle to the 0 PSI graduation on the gauge face, turns on the Check Gauges lamp, and sends a chime tone request to the Central Timer Module (CTM). If the PCM messages indicate that oil pressure is too high, the instrument cluster circuitry moves the gauge needle to the 110 PSI graduation on the gauge face. The engine oil pressure sensor is installed in a threaded hole that penetrates an oil passage of the engine. The engine oil pressure sensor contains a flexible diaphragm and a variable resistor coil. The diaphragm moves in response to changes in the engine oil pressure, which changes the internal electrical resistance of the sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation > Page 1434 Oil Pressure Gauge: Testing and Inspection If the problem being diagnosed is related to oil pressure gauge accuracy, be certain to confirm that the problem is with the gauge and not with the engine oiling system performance. The actual engine oil pressure should be checked with a test gauge and compared to the instrument cluster oil pressure gauge readings before you proceed with gauge diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Increased oil pressure gauge needle activity may be noted with this instrument cluster than with previous designs. This increased needle activity is due to changes that were made to the instrument cluster software that are intended to make the gauge more responsive, and not due to any problem with the engine oiling or oil pressure gauge systems. No attempt at service of these systems should be made, unless the oil pressure gauge readings remain in the high end or the low end of the normal range. Diagnosis of the oil pressure sensor and circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For further diagnosis of the oil pressure gauge and the instrument cluster circuitry, see Instrument Cluster in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Transmission Wiring, Camshaft Position Connector, Distributor, Oilpressure Sending Unit/switch Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1438 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions Oil Pressure Sensor: Technical Service Bulletins Engine Controls/Fuel System - Manual Revisions NUMBER: 26-01-99C GROUP: Miscellaneous DATE: January, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Powertrain 2.5L. 3.9L, 5.2L, 5.9L, 8.0 SFI, Mechanical Injected Diesel Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revision to the Table of Contents Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1443 vi Revision to the Trouble Code Test menu Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1444 538 Revision to the Oil Pressure Sensor test 589, 589A through 589F Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1445 589 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1446 589A Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1447 589B Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1448 589C Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1449 589D Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1450 589E Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1451 589F Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Cover > Component Information > Specifications Oil Pump Cover: Specifications Oil Pump Cover Bolts 95 in.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE @ Curb Idle (Min.*) .............................................................................................................................. ................................................... 41.4 kPa (6 psi) @ 3000 rpm .......................................................... ................................................................................................................... 207 - 552 kPa (30 - 80 psi) Bypass Valve Setting .................................................................................................................... ............................................... 62 - 103 kPa (9 - 15 psi) Switch Actuating pressure ......................................................................................................................................................... 34.5 - 48.3 kPa (5 - 7 psi) CAUTION: If oil pressure is zero at curb idle, DO NOT RUN ENGINE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption Intake Manifold: Customer Interest Engine - Spark Knock/Oil Consumption NUMBER: 09-05-00 GROUP: Engine DATE: Feb.25, 2000 MODELS: 1994 - 1999 (AB) Ram Van 1994 - 1999 (AN) Dakota 1994 - 1999 (BRIBE) Ram Truck 1998 - 1999 (DN) Durango 1994 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan gasket. NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE. SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine. DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed. NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT. Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free. If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by. 1. Allow the engine to reach normal operating temperature. 2. Stop the engine. 3. Disconnect the breather hose from the air cleaner. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1467 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1468 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1469 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1470 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1471 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption Intake Manifold: All Technical Service Bulletins Engine - Spark Knock/Oil Consumption NUMBER: 09-05-00 GROUP: Engine DATE: Feb.25, 2000 MODELS: 1994 - 1999 (AB) Ram Van 1994 - 1999 (AN) Dakota 1994 - 1999 (BRIBE) Ram Truck 1998 - 1999 (DN) Durango 1994 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan gasket. NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE. SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine. DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed. NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT. Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free. If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by. 1. Allow the engine to reach normal operating temperature. 2. Stop the engine. 3. Disconnect the breather hose from the air cleaner. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1477 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1478 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1479 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1480 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1481 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 1487 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 1488 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 1494 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 1495 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1496 Intake Manifold: Specifications PLENUM PAN BOLTS Tighten the bolts, in sequence, as follows: ^ Step 1-Tighten bolts to 2.7 Nm (24 inch lbs.) torque. ^ Step 2-Tighten bolts to 5.4 Nm (48 inch lbs.) torque. ^ Step 3-Tighten bolts to 9.5 Nm (84 inch lbs.) torque. ^ Step 4-Check that all bolts are tighten to 9.5 Nm (84 inch lbs.) torque. MANIFOLD BOLTS Install the intake manifold bolts and tighten as follows: ^ Step 1-Tighten bolts 1 through 4, in sequence, to 8 Nm (72 inch lbs.) torque. Tighten in alternating steps 1.4 Nm (12 inch lbs.) torque at a time. ^ Step 2-Tighten bolts 5 through 12, in sequence, to 8 Nm (72 inch lbs.) torque. ^ Step 3-Check that all bolts are tighten to 8 Nm (72 inch lbs.) torque. ^ Step 4-Tighten all bolts, in sequence, to 16 Nm (12 ft. lbs.) torque. ^ Step 5-Check that all bolts are tighten to 16 Nm (12 ft. lbs.) torque. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1497 Intake Manifold: Description and Operation INTAKE MANIFOLD The aluminum intake manifold is a single plane design with equal length runners. The manifold is sealed by flange side gaskets with front and rear cross-over gaskets. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1498 Intake Manifold: Testing and Inspection INTAKE MANIFOLD DIAGNOSIS An intake manifold leak is characterized by lower than normal manifold vacuum. Also, one or more cylinder may not be functioning. WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE CLOTHING. 1. Start the engine allowing it to warm up. 2. Inspect for disconnected vacuum hoses or hardened or cracked vacuum lines. 3. With a spray bottle, spray a small stream of water on the suspect area. 4. If there is a change in RPM'S, the suspected leak has been found. 5. Repair as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection Intake Manifold: Service and Repair Cleaning and Inspection CLEANING Clean manifold in solvent and blow dry with compressed air. Clean cylinder block front and rear gasket surfaces using a suitable solvent. The plenum pan rail must be clean and dry (free of all foreign material). INSPECTION Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness with a straightedge. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1501 Intake Manifold: Service and Repair Intake Manifold Replacement REMOVAL 1. Disconnect the battery negative cable. 2. Drain the cooling system. 3. Remove the engine cover. 4. Remove the air cleaner. 5. Remove the generator. 6. Disconnect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables. 7. Remove the distributor. Refer to Powertrain Management for the correct procedure. 8. Disconnect and remove the oil pressure sending unit. 9. Disconnect the coolant temperature sending unit(s). 10. Disconnect the injector harness and secure out of the way. 11. Disconnect the IAC, MAP, and TPS connectors from the throttle body. 12. Disconnect the heater hoses and bypass hose. 13. Disconnect the vacuum supply hoses from the intake manifold. 14. Preform the Fuel System Pressure Release procedure (refer to Powertrain Management). 15. Disconnect the fuel supply line. 16. Remove intake manifold bolts. 17. Lift the intake manifold and throttle body out of the engine compartment as an assembly. 18. Remove and discard the flange side gaskets and the front and rear cross-over gaskets. Throttle Body Assembly-MPI 19. Remove the throttle body bolts and lift the throttle body off the intake manifold. Discard the gasket. 20. Remove the plenum pan as follows: a. Turn the intake manifold upside down. Support the manifold. b. Remove the bolts and lift the pan off the manifold. Discard the gasket. INSTALLATION 1. Install the plenum pan, if removed, as follows: a. Turn the intake manifold upside down. Support the manifold. b. Place a new plenum pan gasket onto the seal rail of the intake manifold. Position the pan over the gasket. Align all the gasket and pan holes with the intake manifold. c. Hand start all bolts. d. Tighten the bolts, in sequence, as follows: V6 & V8 ENGINES Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1502 Plenum Pan Bolt Tightening Sequence ^ Step 1-Tighten bolts to 2.7 Nm (24 inch lbs.) torque. ^ Step 2-Tighten bolts to 5.4 Nm (48 inch lbs.) torque. ^ Step 3-Tighten bolts to 9.5 Nm (84 inch lbs.) torque. ^ Step 4-Check that all bolts are tighten to 9.5 Nm (84 inch lbs.) torque. ^ Using a new gasket, install the throttle body, onto the intake manifold. Tighten the bolts to 23 Nm (200 inch lbs.) torque. Cross-Over Gaskets And Locator Dowels 3. Place the 4 plastic locator dowels into the holes in the block. 4. Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, to the four corner joints. An excessive amount of sealant is not required to ensure a leak proof seal. However, an excessive amount of sealant; may reduce the effectiveness of the flange gasket. The sealant should be slightly higher than the crossover gaskets, approx. 5 mm (0.2 in). 5. Install the front and rear cross-over gaskets into the dowels. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1503 Intake Manifold Flange Gasket Alignment 6. Install the flange gaskets. Ensure that the vertical port alignment tab is resting on the deck face of the block. Also the horizontal alignment tabs must be in position with the mating cylinder head gasket tabs. The words MANIFOLD SIDE should be visible on the center of each flange gasket. 7. Carefully lower intake manifold into position on the cylinder block and cylinder heads. Use the alignment dowels in the cross-over gaskets to position the intake manifold. After intake manifold is in place, inspect to make sure seals are in place. 8. Install the intake manifold bolts and tighten as follows: V-6 ENGINE Intake Manifold Bolt Torque Sequence - (V-6) ^ Step 1-Tighten bolts 1 and 2 to 8 Nm (72 inch lbs.) torque. Tighten in alternating steps 1.4 Nm (12 inch lbs.) torque at a time. ^ Step 2-Tighten bolts 3 through 12, in sequence, to 8 Nm (72 inch lbs.) torque. ^ Step 3-Check that all bolts are tighten to 8 Nm (72 inch lbs.) torque. ^ Step 4-Tighten all bolts, in sequence, to 16 Nm (12 ft. lbs.) torque. ^ Step 5-Check that all bolts are tighten to 16 Nm (12 ft. lbs.) torque. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1504 V-8 ENGINE Intake Manifold Bolt Torque Sequence - (V-8) ^ Step 1-Tighten bolts I through 4, in sequence, to 8 Nm (72 inch lbs.) torque. Tighten in alternating steps 1.4 Nm (12 inch lbs.) torque at a time. ^ Step 2-Tighten bolts 5 through 12, in sequence, to 8 Nm (72 inch lbs.) torque. ^ Step 3-Check that all bolts are tighten to 8 Nm (72 inch lbs.) torque. ^ Step 4-Tighten all bolts, in sequence, to 16 Nm (12 ft. lbs.) torque. ^ Step 5-Check that all bolts are tighten to 16 Nm (12 ft. lbs.) torque. 9. Connect the vacuum supply hoses to the intake manifold. 10. Connect the fuel injector harness to the injectors. 11. Connect the coolant temperature sending unit(s). 12. Connect the heater hoses and bypass hose. 13. Install the distributor assembly. Refer to Powertrain Management for the correct procedure. 14. Install and connect the oil pressure sending unit. 15. Connect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables. 16. Install the fuel supply line. 17. Connect the MAP, TPS, and IAC connectors. 18. Install the generator and drive belt. Tighten generator mounting bolts to 41 Nm (30 ft. lbs.) torque. 19. Install the air cleaner. 20. Fill cooling system. 21. Connect the battery negative cable. 22. Start engine and check for leaks. 23. Install the engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation SYSTEM OPERATION The oil pressure gauge gives an indication of the engine oil pressure. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon engine oil pressure messages received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the engine oil pressure sensor and internal programming to decide what engine oil pressure messages are required. The PCM then sends the proper messages to the instrument cluster on the CCD data bus. If the PCM messages indicate that oil pressure is too low, the instrument cluster circuitry moves the gauge needle to the 0 PSI graduation on the gauge face, turns on the Check Gauges lamp, and sends a chime tone request to the Central Timer Module (CTM). If the PCM messages indicate that oil pressure is too high, the instrument cluster circuitry moves the gauge needle to the 110 PSI graduation on the gauge face. The engine oil pressure sensor is installed in a threaded hole that penetrates an oil passage of the engine. The engine oil pressure sensor contains a flexible diaphragm and a variable resistor coil. The diaphragm moves in response to changes in the engine oil pressure, which changes the internal electrical resistance of the sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation > Page 1509 Oil Pressure Gauge: Testing and Inspection If the problem being diagnosed is related to oil pressure gauge accuracy, be certain to confirm that the problem is with the gauge and not with the engine oiling system performance. The actual engine oil pressure should be checked with a test gauge and compared to the instrument cluster oil pressure gauge readings before you proceed with gauge diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Increased oil pressure gauge needle activity may be noted with this instrument cluster than with previous designs. This increased needle activity is due to changes that were made to the instrument cluster software that are intended to make the gauge more responsive, and not due to any problem with the engine oiling or oil pressure gauge systems. No attempt at service of these systems should be made, unless the oil pressure gauge readings remain in the high end or the low end of the normal range. Diagnosis of the oil pressure sensor and circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For further diagnosis of the oil pressure gauge and the instrument cluster circuitry, see Instrument Cluster in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Description and Operation Crankshaft Main Bearing Seal: Description and Operation CRANKSHAFT REAR OIL SEALS The service seal is a two piece, Viton seal. The upper seal half can be installed with crankshaft removed from engine or with crankshaft installed. When a new upper seal is installed, install a new lower seal. The lower seal half can be installed only with the rear main bearing cap removed. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Description and Operation > Page 1514 Crankshaft Main Bearing Seal: Service and Repair The service seal is a 2 piece, Viton seal. The upper seal half can be installed with crankshaft removed from engine or with crankshaft installed. When a new upper seal is installed, install a new lower seal. The lower seal half can only be installed with the rear main bearing cap removed. UPPER SEAL REPLACEMENT-CRANKSHAFT REMOVED 1. Remove the crankshaft. 2. Clean the cylinder block rear cap and block mating surfaces. Make sure the seal groove is free of debris. 3. Lightly oil the new upper seal lip with engine, oil. 4. Install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine. 5. Position the crankshaft into the cylinder block. 6. Lightly oil the new lower seal lip with engine oil. 7. Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine. Sealant Application To Bearing Cap 8. Apply a 5 mm (0.20 in) drop of Loctite 518, or equivalent, on each side of the rear main bearing cap. DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. 9. To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. 10. Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten to 115 Nm (85 ft. lbs.) torque. 11. Install oil pump. 12. Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing. Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. 13. Install new front crankshaft oil seal. 14. Immediately install the oil pan. UPPER SEAL REPLACEMENT-CRANKSHAFT INSTALLED 1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Remove the rear main bearing cap. Remove and discard the old lower oil seal. 4. Carefully remove and discard the old upper oil seal. 5. Lightly oil the new upper seal lips with engine oil. To allow ease of installation of the seal, loosen at least the 2 main bearing caps forward of the rear bearing cap. Clean the cylinder block rear cap mating surface. Make sure the seal groove is free of debris. 6. Rotate the new upper seal into the cylinder block being careful not to shave or cut the outer surface of the seal. To assure proper installation, use the installation tool provided with the kit. Install the new seal with the white paint facing towards the rear of the engine. 7. Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine. 8. Apply 5 mm (0.20 in) drop of Loctite 518, or equivalent, on each side of the rear main bearing cap. DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. Be sure the white paint faces toward the rear of the engine. 9. To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. 10. Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten ALL cap bolts to 115 Nm (85 ft. lbs.) torque. 11. Install oil pump. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Description and Operation > Page 1515 Apply Sealant To Bearing Cap To Block Joint 12. Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing. Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan gasket groove. 13. Immediately install the oil pan. LOWER SEAL REPLACEMENT 1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Remove the rear main bearing cap and discard the old lower seal. 4. Clean the cylinder block rear cap mating surface including the oil pan gasket groove. 5. Carefully install a new upper seal (refer to Upper Seal Replacement-Crankshaft Installed procedure above). 6. Lightly oil the new lower seal lips with engine oil. 7. Install a new lower seal in bearing cap with white paint facing the rear of engine. 8. Apply 5 mm (0.20 in) drop of Loctite 518, or equivalent, on each side of the rear main bearing cap. DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. 9. To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. 10. Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten the cap bolts to 115 Nm (85 ft. lbs.) torque. 11. Install oil pump. 12. Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing. Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. 13. Immediately install the oil pan. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Testing and Inspection Cylinder Head Gasket: Testing and Inspection FAILURE DIAGNOSIS A leaking engine cylinder head gasket usually results in loss of power, loss of coolant, and engine misfiring. An engine cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket. An engine cylinder head gasket leaking between adjacent cylinders is indicated by a loss of power and/or engine misfire. - An engine cylinder head gasket leaking between a cylinder and an adjacent water jacket is indicated by coolant foaming or overheating and loss of coolant. Cylinder To Cylinder Leakage Test To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures outlined in Cylinder Compression Pressure Test. An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a 50-70% reduction in compression pressure. Cylinder To Water Jacket Leakage Test WARNING: Use extreme caution when the engine is operating. Do not stand in a direct line with the fan. Do not put your hands near the pulleys, belts, oft the fan. Do not wear loose clothing. Remove the radiator cap. Start the engine and allow it to warm up until the engine thermostat opens. If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant. If bubbles are not visible, install a radiator pressure tester and pressurize the coolant system. If a cylinder is leaking combustion pressure into the water jacket, the tester pointer will pulsate with every combustion stroke of the cylinder. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair The oil seal can be replaced without removing the timing chain cover provided the cover is not misaligned. 1. Disconnect the negative cable from the battery. 2. Remove vibration damper. 3. If front seal is suspected of leaking, check front oil seal alignment to crankshaft. The seal installation/alignment tool 6635, should fit with minimum interference. If tool does not fit, the cover must be removed and installed properly. 4. Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to damage the crankshaft seal bore of cover. Placing Oil On Installation Tool 6635 5. Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635. Seat the oil seal in the groove of the tool. Position Tool And Seal Onto Crankshaft 6. Position the seal and tool onto the crankshaft. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1522 Installing Oil Seal 7. Using the vibration damper bolt, tighten the bolt to draw the seal into position on the crankshaft. 8. Remove the vibration damper bolt and seal installation tool. 9. Inspect the seal flange on the vibration damper. 10. Install the vibration damper. 11. Connect the negative cable to the battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption Intake Manifold Gasket: Customer Interest Engine - Spark Knock/Oil Consumption NUMBER: 09-05-00 GROUP: Engine DATE: Feb.25, 2000 MODELS: 1994 - 1999 (AB) Ram Van 1994 - 1999 (AN) Dakota 1994 - 1999 (BRIBE) Ram Truck 1998 - 1999 (DN) Durango 1994 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan gasket. NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE. SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine. DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed. NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT. Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free. If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by. 1. Allow the engine to reach normal operating temperature. 2. Stop the engine. 3. Disconnect the breather hose from the air cleaner. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1531 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1532 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1533 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1534 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1535 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption Intake Manifold Gasket: All Technical Service Bulletins Engine - Spark Knock/Oil Consumption NUMBER: 09-05-00 GROUP: Engine DATE: Feb.25, 2000 MODELS: 1994 - 1999 (AB) Ram Van 1994 - 1999 (AN) Dakota 1994 - 1999 (BRIBE) Ram Truck 1998 - 1999 (DN) Durango 1994 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan gasket. NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE. SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine. DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed. NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT. Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free. If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by. 1. Allow the engine to reach normal operating temperature. 2. Stop the engine. 3. Disconnect the breather hose from the air cleaner. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1541 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1542 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1543 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1544 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1545 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Cylinder Head Off Valve Guide Seal: Service and Repair Cylinder Head Off Refer to Valves, Intake/Exhaust, Service and Repair for procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Cylinder Head Off > Page 1550 Valve Guide Seal: Service and Repair Cylinder Head On Refer to Valve Spring, Service and Repair for procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Transmission Wiring, Camshaft Position Connector, Distributor, Oilpressure Sending Unit/switch Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1555 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions Oil Pressure Sensor: Technical Service Bulletins Engine Controls/Fuel System - Manual Revisions NUMBER: 26-01-99C GROUP: Miscellaneous DATE: January, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Powertrain 2.5L. 3.9L, 5.2L, 5.9L, 8.0 SFI, Mechanical Injected Diesel Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revision to the Table of Contents Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1560 vi Revision to the Trouble Code Test menu Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1561 538 Revision to the Oil Pressure Sensor test 589, 589A through 589F Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1562 589 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1563 589A Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1564 589B Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1565 589C Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1566 589D Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1567 589E Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1568 589F Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt ....................................................................................................................... .................................................... 68 Nm (50 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Measuring Timing Chain Stretch Timing Chain: Service and Repair Measuring Timing Chain Stretch NOTE: To access timing chain Refer to Timing Cover. 1. Place a scale next to the timing chain so that any movement of the chain may be measured. 2. Place a torque wrench and socket over camshaft sprocket attaching bolt. Apply torque in the direction of crankshaft rotation to take up slack; 41 Nm (30 ft. lbs.) torque with cylinder head installed or 20 Nm (15 ft. lbs.) torque with cylinder head removed. With a torque applied to the camshaft sprocket bolt, crankshaft should not be permitted to move. It may be necessary to block the crankshaft to prevent rotation. Measuring Timing Chain Wear And Stretch 3. Hold a scale with dimensional reading even with the edge of a chain link. With cylinder heads installed, apply 14 Nm (30 ft. lbs.) torque in the reverse direction. With the cylinder heads removed, apply 20 Nm (15 ft. lbs.) torque in the reverse direction. Note the amount of chain movement. 4. Install a new timing chain, if its movement exceeds 3.175 mm (1/8 inch). 5. If chain is not satisfactory, remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets. 6. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores. 7. Place timing chain around both sprockets. 8. Turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in camshaft sprocket. 9. Lift sprockets and chain (keep sprockets tight against the chain in position as described). Alignment Of Timing Marks 10. Slide both sprockets evenly over their respective shafts and use a straightedge to check alignment of timing marks. 11. Install the camshaft bolt. Tighten the bolt to 47 Nm (35 ft. lbs.) torque. 12. Check camshaft end play. The end play should be 0.051-0.152 mm (0.002-0.006 inch) with a new thrust plate and up to 0.254 mm (0.010 inch) with a used thrust plate. If not within these limits install a new thrust plate. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Measuring Timing Chain Stretch > Page 1577 Timing Chain: Service and Repair Timing Chain Replacement REMOVAL 1. Disconnect battery negative cable. 2. Remove Timing Cover. Alignment Of Timing Marks 3. Re-install the vibration damper bolt finger tight. Using a suitable socket and breaker bar, rotate the crankshaft to align timing marks. 4. Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets. INSTALLATION 1. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores. 2. Place timing chain around both sprockets. 3. Turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in camshaft sprocket. 4. Lift sprockets and chain (keep sprockets tight against the chain in position as described). 5. Slide both sprockets evenly over their respective shafts and use a straightedge to check alignment of timing marks. 6. Install the camshaft bolt. Tighten the bolt to 68 Nm (50 ft. lbs.) torque. 7. Check camshaft end play. The end play should be 0.051-0.152 mm (0.002-0.006 inch) with a new thrust plate and up to 0.254 mm (0.010 inch) with a used thrust plate. If not within these limits install a new thrust plate. 8. Install the timing chain cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Chain Case Cover Bolts 30 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1581 Timing Cover: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Drain cooling system. 3. Remove the serpentine belt. 4. Remove water pump. Refer to Cooling System 5. Remove power steering pump. Refer to Steering and Suspension. 6. Remove vibration damper. 7. Remove fuel lines (refer to Powertrain Management). 8. Loosen oil pan bolts and remove the front bolt at each side. 9. Remove the cover bolts. 10. Remove chain case cover and gasket using extreme caution to avoid damaging oil pan gasket. Removal Of Front Crankshaft Oil Seal 11. Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to damage the crankshaft seal surface of cover. CLEANING Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. The water pump mounting surface must be cleaned. INSTALLATION 1. Using a new cover gasket, carefully install chain case cover to avoid damaging oil pan gasket. Use a small amount of Mopar Silicone Rubber Adhesive Sealant, or equivalent, at the joint between timing chain cover gasket and the oil pan gasket. Finger tighten the timing chain cover bolts at this time. CAUTION: If chain cover is replaced for any reason, make sure the oil hole (passenger side of cover) is plugged. Placing Oil Seal On Installation Tool 6635 2. Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635. Seat the oil seal in the groove of the tool. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1582 Position Tool And Seal Onto Crankshaft 3. Position the seal and tool onto the crankshaft. 4. Tighten the 4 lower chain case cover bolts to 13N.m (10 ft.lbs.) to prevent the cover from tipping during seal installation. Installing Oil Seal 5. Using the vibration damper bolt, tighten the bolt to draw the seal into position on the crankshaft. 6. Loosen the 4 bolts tightened in step 4 to allow realignment of front cover assembly. 7. Tighten chain case cover bolts to 41 Nm (30 ft. lbs.) torque. Tighten oil pan bolts to 24 Nm (215 inch lbs.) torque. 8. Remove the vibration damper bolt and seal installation tool. 9. Install vibration damper. 10. Install water pump and housing assembly using new gaskets (refer to Cooling System). Tighten bolts to 41 Nm (30 ft. lbs.) torque. 11. Install power steering pump. Refer to Steering and Suspension. 12. Install the serpentine belt. 13. Install the cooling system fan. Tighten the bolts to 23 Nm (17 ft. lbs.) torque. 14. Position the fan shroud and install the bolts. Tighten the bolts to 11 Nm (95 inch lbs.) torque. 15. Fill cooling system. 16. Connect the negative cable to the battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage NO: 14-03-98 GROUP: Fuel DATE: May 1, 1998 SUBJECT: Fuel Pressure Gauge Adapter Usage MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) DISCUSSION: Currently, four different fuel pressure adapters are required, depending on application, to attach a fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications Fuel Pressure: Pressure, Vacuum and Temperature Specifications Fuel Pressure Engine at curb idle ............................................................................................................................... ........................................ 339 ± 34 kPa (49.2 ± 5 psi) Pressure Leakdown (fuel pump not engaged) ................................................................................................................. Not fall below 30 psi for 5 minutes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 1590 Fuel Pressure: Capacity Specifications NOTE: Before performing this test, verify fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. - Refer to the Fuel Pressure Release Procedure. 2. Disconnect the fuel supply line at fuel rail. - Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. - Insert other end of Adaptor Tool hose into a graduated container. 4. Remove the fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. - Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. - Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test Fig 9 Connecting Adaptor Tool -- Typical Fig. 8 Installing Adapter Tool And Pressure Gauge NOTE: Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: Fuel pressure bleeding past a fuel injector(s). - Fuel pressure bleeding past the check valve in the fuel pump module. 1. Disconnect the fuel inlet line at fuel rail. - On some engines, air cleaner housing removal may be necessary before fuel line disconnection. 2. Connect the appropriate Fuel Line Pressure Test Adapter Tool (number 6539, 6631, 6541 or 6923) between the disconnected fuel line and fuel rail (Fig. 9) or (Fig. 10). 3. Connect the 0-414 kPa (0-60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. - The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 4. Start engine and bring to normal operating temperature. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 1593 5. Observe test gauge. Normal operating pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). 6. Shut engine off. 7. Pressure should not fall below 30 psi for five minutes. 8. If pressure falls below 30 psi, it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 9. Again, start engine and bring to normal operating temperature. 10. Shut engine off. 11. Testing for fuel injector or fuel rail leakage: - Clamp off the rubber hose portion of Adaptor Tool between the fuel rail and the test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a fuel injector or the fuel rail is leaking. 12. Testing for fuel pump check valve, filter/regulator check valve or fuel tube/line leakage: - Clamp off the rubber hose portion of Adaptor Tool between the vehicle fuel line and test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a leak may be found at a fuel tube/line. - If no leaks are found at fuel tubes or lines, one of the check valves in either the electric fuel pump or filter/ regulator may be leaking. NOTE: A quick loss of pressure usually indicates a defective check valve in the filter/regulator. A slow loss of pressure usually indicates a defective check valve in the electric fuel pump. The electric fuel pump is not serviced separately -- Replace the fuel pump module assembly. The filter/ regulator may be replaced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/installation for additional information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 1594 Fuel Pressure: Testing and Inspection Fuel Pressure Test Fuel Pressure Test Gauge NOTE: Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test, fuel pump amperage test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow hack into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. WARNING: The fuel system is under constant fuel pressure even with the engine off. Before disconnecting fuel line at fuel rail, this pressure must be released. Refer to the fuel system pressure release procedure. NOTE: To perform this test you will need to remove the engine cover. 1. Remove the protective cap at the fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port pressure fitting on the fuel rail. 2. Start and warm the engine and note pressure gauge reading. Fuel pressure should be 3.39 kPa +/- 34 kPa (49.2 psi +/- 5 psi) at idle. 3. If engine runs but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, replace fuel pump module assembly. Refer to Fuel Pump Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel filter/fuel pressure regulator. Certain filter/regulators may be serviced separately and some require the replacement of the fuel pump module assembly Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 1595 Fuel Pressure: Testing and Inspection Fuel Pump Amperage Test This amperage (current draw) test is to be done in conjunction with the Fuel Pump Pressure Test, Fuel Pump Capacity Test and Fuel Pressure Leak Down Test. Before performing the amperage test, be sure the temperature of the fuel tank is above 50° F (10° C). The DRB Scan Tool along with the DRB Low Current Shunt (LCS) adapter and its test leads will be used to check fuel pump amperage specifications. Low Current Shunt Adapter 1. Obtain LCS adapter. 2. Plug cable from LCS adapter into DRB scan tool at SET 1 receptacle. 3. Plug DRB into vehicle 16-way connector (data link connector). 4. Connect (-) and (+) test cable leads into LCS adapter receptacles. Use 10 amp (10A +) receptacle and common (-) receptacles. 5. Gain access to MAIN MENU on DRB screen. 6. Press DVOM button on DRB. 7. Using left/right arrow keys, highlight CHANNEL 1 function on DRB screen. 8. Press ENTER three times. 9. Using up/down arrow keys, highlight RANGE on DRB screen (screen will default to 2 amp scale). 10. Press ENTER to change 2 amp scale to 10 amp scale. This step must be done to prevent damage to DRB scan tool or LCS adapter (blown fuse). 11. Remove cover from Power Distribution Center (PDC). 12. Remove fuel pump relay from PDC. Refer to label on PDC cover for relay location. WARNING: BEFORE PROCEEDING TO NEXT STEP, NOTE THE FUEL PUMP WILL BE ACTIVATED AND SYSTEM PRESSURE WILL BE PRESENT. THIS WILL OCCUR AFTER CONNECTING TEST LEADS FROM LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES. THE FUEL PUMP WILL OPERATE EVEN WITH IGNITION KEY IN OFF POSITION. BEFORE ATTACHING TEST LEADS, BE SURE ALL FUEL LINES AND FUEL SYSTEM COMPONENTS ARE CONNECTED. CAUTION: To prevent possible damage to the vehicle electrical system and LCS adapter, the test leads must be connected into relay cavities exactly as shown in following steps. Depending upon vehicle model, year or engine configuration, three different types of relays may be used: Type-1, type-2 and type-3. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 1596 Starter Relay 13 If equipped with type-1 relay, attach test leads from LCS adapter into PDC relay cavities number 30 and 87. For location of these cavities, refer to numbers stamped to bottom of relay. Type-2 Relay 14. If equipped with type-2 relay, attach test leads from LCS adapter into PDC relay cavities number 30 and 87. For location of these cavities, refer to numbers stamped to bottom of relay. Type-3 Relay 15. If equipped with type-3 relay, attach test leads from LCS adapter into PDC relay cavities number 3 and 5. For location of these cavities, refer to numbers stamped to bottom of relay. 16. When LCS adapter test leads are attached into relay cavities, fuel pump will be activated. Determine fuel pump amperage on DRB screen. Amperage should be below 10.0 amps. If amperage is below 10.0 amps, and specifications for the Fuel Pump Pressure, Fuel Pump Capacity and Fuel Pressure Leak Down tests were met, the fuel pump module is OK. 17. If amperage is more than 10.0 amps, replace fuel pump module assembly The electric fuel pump is not serviced separately. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 1597 18. Disconnect test leads from relay cavities immediately after testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 1598 Fuel Pressure: Testing and Inspection Fuel Pump Capacity Test NOTE: Before performing this test, verify fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. - Refer to the Fuel Pressure Release Procedure. 2. Disconnect the fuel supply line at fuel rail. - Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. - Insert other end of Adaptor Tool hose into a graduated container. 4. Remove the fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. - Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. - Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions Air/Fuel Mixture: Technical Service Bulletins Fuel System/Engine Controls - Manual Revisions NUMBER: 26-02-99A GROUP: Miscellaneous DATE: February, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revision to the Diagnostic Trouble Codes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1603 45 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1604 46 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1605 47 Revision to the Throttle Position Sensor connector pin outs Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1606 152 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1607 156 Revision to the Fuel System Rich test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1608 316 Revisions to the Throttle Position sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1609 620 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1610 622 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ......................................................... 500 to 900 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1614 Idle Speed: Testing and Inspection The following test procedure has been developed to check throttle body calibrations for correct idle conditions. The procedure should be used to diagnose the throttle body for conditions that may cause idle problems. This procedure should be used only after normal diagnostic procedures have failed to produce results that indicate a throttle body related problem. Be sure to check for proper operation of the idle air control motor before performing this test. Fig. 73 Fixed Orifice Tool A special fixed orifice tool (number 6714) must be used for the following test. 1. Start the engine and bring to operating temperature. Be sure all accessories are off before performing this test. 2. Shut off the engine and remove the air cleaner element housing. Fig. 74 Install Orifice Tool 3. Disconnect the vacuum line at the PCV valve. 4. Install the 0.185 inch orifice tool (number 6714) into the disconnected vacuum line in place of the PCV valve. Fig. 75 Idle Purge Line Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1615 5. Disconnect the idle purge vacuum line from fitting at throttle body This vacuum line is located on the front of throttle body next to the MAP sensor. Cap the fitting at throttle body after vacuum line has been removed. 6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under the instrument panel to the left of the steering column. 7. Start the engine. 8. Using the DRB scan tool, scroll through the menus as follows: select-System, select-Engine, select-Fuel and Ignition, select-Actuator Tests, select Engine rpm and select-Minimum Air Flow. 9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm. The idle rpm should be between 500 and 900 rpm. If the idle speed is outside of these specifications, replace the throttle body. 10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV valve. 13. Install air cleaner element housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair Fig 52 Air Cleaner Components -- Typical REMOVAL 1. From engine compartment, remove plastic air intake tube at front of air cleaner housing. Tube snaps onto air cleaner housing. 2. Remove engine cover. 3. Pull crankcase breather/filter (straight up) from engine valve cover. 4. Remove wing nut and remove air cleaner assembly from throttle body. INSTALLATION 1. Position air cleaner housing to throttle body. 2. If housing-to-throttle body mounting stud is being installed, tighten to 10 N.m (90 in. lbs.) torque. 3. Tighten wingnut to 1.5 N.m (15 in. lbs.) torque. 4. Push crankcase breather/filter into valve cover. 5. Install plastic air intake tube to housing. 6. Install engine cover. AIR CLEANER ELEMENT Housing removal is not necessary for element (filter) replacement. REMOVAL 1. Remove engine cover. 2. Remove wingnut and remove cover from housing. 3. Remove air cleaner element from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Install housing cover to housing. 3. Install wingnut. 4. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair NOTE: Use following procedure if fuel rail is or is not equipped with fuel pressure test port. 1. Remove fuel fill cap. 2. The fuel filler tube contains a spring-loaded flap (door) located below fuel fill cap. The flap is used as a secondary way of sealing fuel tank if fuel fill cap has not been properly tightened. It is part of EVAP monitor system when vehicle is equipped with a Leak Detection Pump (LDP). The vehicle may be equipped with flap installed into fuel filler tube even though vehicle is not equipped with LDP and EVAP monitor system. Place a nonmetallic object into fuel fill tube and press on flap to relieve any tank pressure. 3. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 7. Unplug connector from any injector. 8. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 9. Connect other end of jumper wire to positive side of battery. 10. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 11. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 12. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 13. Disconnect quick-connect fitting at fuel rail. 14. Return fuel pump relay to PDC. 15. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1638 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1639 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1640 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1641 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1642 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1643 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1649 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1650 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1651 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1652 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1653 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1654 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1655 Ignition Cable: Specifications MINIMUM = MAXIMUM 250 Ohms Per Inch = 1000 Ohms Per Inch 3000 Ohms Per Foot = 12,000 Ohms Per Foot Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1656 Ignition Cable: Description and Operation SYSTEM OPERATION Spark plug cables are sometimes referred to as secondary ignition wires. These cables transfer electrical current from the ignition coil(8) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1657 Ignition Cable: Testing and Inspection Heat Shields Check the spark plug cable connections for good contact at the coil(s), distributor cap towers, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, distributor and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean high voltage ignition cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Spark plug cable heat shields are pressed into the cylinder head to surround each spark plug cable boot and spark plug . These shields protect the spark plug boots from damage (due to intense engine heat generated by the exhaust manifolds) and should not be removed. After the spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat shield. Testing When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment manufacturer. If an oscilloscope is not available, spark plug cables may be tested as follows: CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. With the engine running, remove spark plug cable from spark plug (one at a time) and hold next to a good engine ground. If the cable and spark plug are in good condition, the engine rpm should drop and the engine will run poorly If engine rpm does not drop, the cable and/or spark plug may not be operating properly and should be replaced. Also check engine cylinder compression. With the engine not running, connect one end of a test probe to a good ground. Start the engine and run the other end of the test probe along the entire length of all spark plug cables. If cables are cracked or punctured, there will be a noticeable spark jump from the damaged area to the test probe. The cable running from the ignition coil to the distributor cap can be checked in the same manner. Cracked, damaged or faulty cables should be replaced with resistance type cable. This can be identified by the words ELECTRONIC SUPPRESSION printed on the cable jacket. Use an ohmmeter to test for open circuits, excessive resistance or loose terminals. If equipped, remove the distributor cap from the distributor. Do not remove cables from cap. Remove cable from spark plug. Connect ohmmeter to spark plug terminal end of cable and to corresponding electrode in distributor cap. Resistance should be 250 to 1000 Ohms per inch of cable. If not, remove cable from distributor cap tower and connect ohmmeter to the terminal ends of cable. If resistance is not within specifications as found in the SPARK PLUG CABLE RESISTANCE chart, replace the cable. Test all spark plug cables in this manner. Spark Plug Cable Resistance MINIMUM = MAXIMUM 250 Ohms Per Inch = 1000 Ohms Per Inch 3000 Ohms Per Foot = 12,000 Ohms Per Foot To test ignition coil-to-distributor cap cab]e, do not remove the cable from the cap. Connect ohmmeter to rotor button (center contact) of distributor cap and terminal at ignition coil end of cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, remove the cable from the distributor cap. Connect the ohmmeter to the terminal ends of the cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, replace the cable. Inspect the ignition coil tower for cracks, burns or corrosion. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1658 Ignition Cable: Service and Repair REMOVAL AND INSTALLATION Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Engine Firing Order Install cables into the proper engine cylinder firing order. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Cap Inspection-External-Typical Cap Inspection-Internal-Typical Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. The machined surface of a terminal end (faces toward rotor) will indicate some evidence of erosion from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Rotor Inspection-Typical Visually inspect the rotor for cracks, evidence of corrosion or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... ..................................................... 0.89 mm (0.035 in) Torque ............................................................ ............................................................................................................................................... 41 Nm (30 ft lb) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1669 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ..................................................................... RC12YC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1670 Spark Plug: Description and Operation SYSTEM OPERATION All engines use resistor type spark plugs. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Spark plugs that have low milage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1671 Spark Plug: Testing and Inspection Normal Operating Spark Plug Cable Resistance The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Cold Fouling/Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operating times (short trips). Wet Fouling Or Gas Fouling A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Oil Or Ash Encrusted Oil Or Ash Encrusted If one or more spark plugs are oil or oil ash encrusted, evaluate engine condition for the cause of oil entry into that particular combustion chamber. Electrode Gap Bridging Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1672 Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Scavenger Deposits Scavenger Deposit Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy, but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Chipped Electrode Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Preignition Damage Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1673 Preignition Damage Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Spark Plug Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1674 Spark Plug: Service and Repair Heat Shields Spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. PLUG REMOVAL 1. Remove engine cover. 2. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result, 3. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber. 4. Remove the spark plug using a quality socket with a rubber or foam insert. 5. Inspect the spark plug condition. Plug Cleaning The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator arid will cause plug misfire. Plug Gap Adjustment Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. Spark Plug Gap V-8 Engines: 1.01 mm (.040 in). PLUG INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. when replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 N.m (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi) from cylinder to cylinder. If cylinder(s) have abnormally low compression pressures, repeat procedure. - If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a problem in the cylinder. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should NOT be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1678 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. Minimum cylinder compression pressure is 689 kPa (100 psi). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Mounting Bolts 30 ft.lb Water Pump Pulley 16 ft.lb Water Pump-to-Chain Case Cover Bolt 31 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1685 Water Pump: Description and Operation A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in a bearing pressed into the water pump body. The body has a small hole for ventilation. The water pump seals are lubricated by antifreeze in the coolant mixture. Additional lubrication is not necessary. A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core. The water pump on all models can be removed without discharging the air conditioning system (if equipped). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Pump Replacement Water Pump: Service and Repair Water Pump Replacement REMOVAL The water pump on all engines is bolted directly to the engine timing chain case/cover. A gasket is used as a seal between the water pump and timing chain case/cover. If water pump is replaced because of bearing/shaft damage or leaking shaft seal, the mechanical cooling fan assembly should also be inspected. Inspect for fatigue cracks, loose blades or loose rivets that could have resulted from excessive vibration. Replace fan if any of these conditions are found. Also check condition of the thermal viscous fan drive. 1. Disconnect negative battery cable from battery. 2. Drain cooling system. 2. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. 3. Remove the plastic air cleaner intake tube. 4. Remove two-piece fan shroud. Remove lower half first. Hose Clamp Tool-Typical WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. Clamp Number/Letter Location CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 5. Remove upper radiator hose at radiator. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Pump Replacement > Page 1688 Fan Blade And Viscous Fan Drive-Typical 6. The thermal viscous fan drive is attached (threaded) to the water pump hub shaft. Remove the fan/fan drive assembly from water pump by turning the mounting nut counterclockwise (as viewed from front). Threads on the fan drive are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be used. Place a bar or screwdriver between the water pump pulley bolts to prevent the pulley from rotating. 7. If water pump is being replaced, do not unbolt fan blade assembly from the thermal viscous fan drive. 8. Remove fan blade/fan drive assembly from vehicle. 9. After removing fan blade/fan drive assembly, do not place the thermal viscous fan drive in the horizontal position. If stored horizontally, the silicone fluid in the viscous drive could drain into its bearing assembly and contaminate the bearing lubricant. 10. Do not remove the water pump pulley bolts at this time. Automatic Belt Tensioner-Typical 11. Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded automatic belt tensioner. Relax the tension from the belt by rotating the tensioner clockwise (as viewed from front). When all belt tension has been relaxed, remove accessory drive belt. 12. Remove the four water pump pulley-to-water pump hub bolts and remove pulley from engine. 13. Remove the lower radiator hose at water pump. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Pump Replacement > Page 1689 Coolant Return Tube-Typical 14. Loosen heater hose coolant return tube mounting bolt and remove tube from water pump. Discard the old tube O-ring. 15. Remove the seven water pump mounting bolts. 16. Loosen the clamp at the water pump end of bypass hose. Slip the bypass hose from the water pump while removing pump from engine. Do not remove the clamp from the bypass hose. 17. Discard old gasket. CAUTION: Do not pry the water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks. INSTALLATION Water Pump Bolts-Typical 1. Clean gasket mating surfaces. 2. Using a new gasket, install water pump to engine as follows: Guide water pump fitting into bypass hose as pump is being installed. Install water pump mounting bolts. Tighten bolts in a criss-cross pattern to 40 Nm (30 ft. lbs.) torque. 3. Position bypass hose clamp to bypass hose. 4. Spin water pump to be sure that pump impeller does not rub against timing chain case/cover. 5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation. 6. Install coolant return tube and its mounting bolt to engine. Be sure the slot in tube bracket is bottomed to mounting bolt. This will properly position return tube. 7. Connect radiator lower hose to water pump. 8. Connect heater hose and hose clamp to coolant return tube. 9. Install water pump pulley. Tighten bolts to 27 Nm (20 ft. lbs.) torque. Place a bar or screwdriver between water pump pulley bolts to prevent pulley from rotating. 10. Relax tension from automatic belt tensioner. Install drive belt. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Pump Replacement > Page 1690 Belt Routing-All Engines CAUTION: When installing the serpentine accessory drive belt, belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to the Belt Routing Label for correct belt routing. The correct belt with correct length must be used. The provided belt routing schematics are published from the latest information available at the time of publication. If anything differs between these schematics and the Belt Routing Label, use the schematics on Belt Routing Label. This label is located in the engine compartment. 11. Install the fan blade/viscous fan drive assembly to water pump shaft. 12. Install fan shroud. 13. Install plastic air cleaner intake tube. 14. Install upper radiator hose and hose clamp to radiator. 15. Fill cooling system. 16. Connect negative battery cable. 17. Start and warm the engine. Check for leaks. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Pump Replacement > Page 1691 Water Pump: Service and Repair Cleaning and Inspection Replace water pump assembly if it has any of the following conditions: ^ The body is cracked or damaged ^ Water leaks from the shaft seal. This is evident by traces of coolant below the vent hole ^ Loose or rough turning bearing. Also inspect thermal viscous fan drive ^ Impeller rubs either the pump body or timing chain case/cover Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity ................................................................................................................................. ...................................................... 12.3 L (13.1 Qts.) NOTES: - Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to manufacturing tolerances and refill procedures. - Add 0.9L (1 Qt.) if equipped with an auxiliary rear mounted heater. - Capacities shown include vehicles with air conditioning and/or heavy-duty cooling systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1697 Coolant: Fluid Type Specifications The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37° C (-35° F). The antifreeze concentration must always be a minimum of 44%, year round, in all climates. If percentage is lower than 44%, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. 100 Percent Ethylene-Glycol Should Not Be Used Use of 100 Percent Ethylene-Glycol will cause formation of additive deposits in the system, as the corrosive inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise as high as 149° C (300° F). this temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 % ethylene-glycol freezes at 22° C (-8° F). Propylene-Glycol Formulations Should Not Be Used Propylene-glycol formulations do not meet the required specifications. It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32° C (-26° F), 5 degrees higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at 96.5 kPa (14 PSI), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can result in boil-over and freeze up. Propylene-Glycol also has a poorer heat transfer characteristics than ethylene-glycol. This can increase cylinder head temperatures under certain conditions. Propylene-Glycol/Ethylene-Glycol Mixtures Should Not Be Used Propylene-glycol/ethylene-glycol mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the coling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining the freeze point will not be accurate. Both the refractive index and specific gravity differ between the ethylene-glycol and propylene-glycol. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Coolant Performance Coolant: Description and Operation Coolant Performance ETHYLENE-GLYCOL MIXTURES The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle open ating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37 deg. C 05 deg. F). The anti-freeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7 deg. C (-90 deg. F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. 100 Percent Ethylene-Glycol Should Not Be Used in Chrysler Vehicles Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149 deg. C (300) deg. F). This temperature is hot, enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22 deg. C (-8 deg. F). Propylene-glycol Formulations Should Not Be Used in Chrysler Vehicles Propylene-glycol formulations do not meet Chrysler coolant specifications. It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32 deg. C (-26 deg. F). 5 deg. C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125 deg. C (257 deg. F ) at 96.5 kPa (14 psi), compared to 128 deg. C (263 deg. F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up in Chrysler vehicles, which are designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol/Ethylene-glycol Mixtures Should Not Be Used in Chrysler Vehicles Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Coolant Performance > Page 1700 Coolant: Description and Operation Selection and Additives The presence of aluminum components in the cooling system requires strict corrosion protection. Maintain coolant at specified level with a mixture of ethylene-glycol based antifreeze and water. Chrysler Corporation recommends Mopar Antifreeze or equivalent. If coolant becomes contaminated or looses color, drain and flush cooling system and fill with correctly mixed solution. A 0.25 percent emulsifiable oil is added to the radiator at the factory to prevent solder corrosion. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Page 1701 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Description and Operation Coolant Line/Hose: Description and Operation Radiator Hoses-Typical Rubber hoses route coolant to and from the radiator, intake manifold and heater core. Radiator lower hoses are spring-reinforced to prevent collapse from water pump suction at moderate and high engine speeds. Inspect the hoses at regular intervals. Replace hoses that are cracked, feel brittle when squeezed or swell excessively when the system is pressurized. The use of molded replacement hoses is recommended. When performing a hose inspection, inspect the radiator lower hose for proper position and condition of the spring. Hose Clamp Tool-Typical WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Description and Operation > Page 1705 Clamp Number/Letter Location CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. For all vehicles: In areas where specific routing and clamps are not provided, be sure that hoses are positioned with sufficient clearance. Check clearance from exhaust manifolds and pipe, fan blades, drive belts and sway bars. Improperly positioned hoses can be damaged, resulting in coolant loss and engine overheating. Ordinary worm gear type hose clamps (when equipped) can be removed with a straight screwdriver or a hex socket. To prevent damage to hoses or clamps, the hose clamps should be tightened to 4 Nm (34 inch lbs.) torque. Do not over tighten hose clamps. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair Coolant Reservoir: Service and Repair REMOVAL 1. Disconnect the battery negative cable. 2. Remove the windshield washer reservoir. 3. Remove overflow hose at reserve/overflow tank. Coolant Recovery Bottle-Removal/Installation 4. Remove the two bolts at top of tank and remove tank. A slot is located on the radiator support panel (sheet metal) to support the lower part of tank. Slip tank from this slot. INSTALLATION 1. Slip the tank into the slot on radiator support. 2. Install bolts and tighten to 6 Nm (50 inch lbs.) torque. 3. Install overflow hose to tank. 4. Install the windshield washer reservoir. 5. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Technical Service Bulletins > Engine Cooling Fan - Roaring Noise Explanation Fan Blade: Technical Service Bulletins Engine Cooling Fan - Roaring Noise Explanation NO: 07-05-98 GROUP: Cooling DATE: Sep. 4, 1998 SUBJECT: Engine Cooling Fan Noise MODELS: 1998 - 1999 (AB) Ram Van/Wagon 1997 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: Some vehicles may exhibit an engine cooling fan "roar" noise. This noise is created by a large cooling fan that is required to provide optimum cooling for low vehicle speed operation in hot weather conditions and for heavy trailer towing. Since the large cooling fan is unnecessary in most operating conditions, these vehicles are also equipped with viscous fan drives that allow the fan to operate at variable speeds based upon temperature loads. The viscous fan drive will engage the fan for maximum cooling when temperatures are high and allow the fan to operate at slower speeds when temperatures are low. In addition, at engine start-up, the viscous fan drive engages the fan for maximum cooling until the fluid in the viscous clutch can dissipate out of the clutch drive grooves allowing the fan to operate at a slower speed. Because of the viscous fan drive, the noise may occur during high temperature conditions and for the first 1-2 minutes of operation. Due to the roar of the fan, customers may also complain of a perceived loss of power, automatic transmission slippage, or that the transmission is slaying into a low gear too long (delayed upshift). Customers concerned about this noise should be advised that this condition is normal and no repair attempts should be made. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair > Removal and Installation Fan Blade: Service and Repair Removal and Installation For additional information, also refer to the Fan Clutch. REMOVAL Fan belt removal is not necessary to remove cooling system fan. 1. Disconnect the negative battery cable at battery. 2. Remove the plastic air cleaner intake tube. 3. Remove two-piece fan shroud. Remove lower half first. Fan Blade/Viscous Fan Drive Assembly 4. The thermal viscous fan drive/fan blade assembly is attached (threaded) to the water pump hub shaft. Remove the fan blade/fan drive assembly from water pump by turning the mounting nut counterclockwise (as viewed from front). Threads on the viscous fan drive are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be used. Place a bar or screwdriver between the water pump pulley bolts to prevent the pulley from rotating. Do not unbolt fan blade assembly from the viscous fan drive at this time. 5. After removing fan blade/fan drive assembly do not place the thermal viscous fan drive in the horizontal position. If stored horizontally, the silicone fluid in the viscous fan drive could drain into its bearing assembly and contaminate the bearing lubricant. CAUTION: Do not remove the water pump pulley-to-water pump bolts. This pulley is under spring tension. 6. Remove the four bolts securing the fan blade assembly to the viscous fan drive. INSTALLATION 1. Install fan blade assembly to viscous fan drive. Tighten bolts to 23 Nm (17 ft. lbs.) torque. 2. Install the fan blade/viscous fan drive assembly to water pump shaft. 3. Install fan shroud. 4. Install air cleaner intake tube. 5. Connect negative battery cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair > Removal and Installation > Page 1716 Fan Blade: Service and Repair Cleaning and Inspection The fan cannot be repaired. If the fan is damaged, it must be replaced. Inspect the fan as follows: 1. Remove fan blade and viscous fan drive assembly from engine. Refer to the preceding Removal procedure. 2. Remove fan blade assembly from viscous fan drive unit (four bolts). 3. Lay fan on a flat surface with leading edge facing down. With tip of blade touching flat surface, replace fan if clearance between opposite blade and surface is greater than 2.0 mm (0.090 inch). Rocking motion of opposite blades should not exceed 2.0 mm (0.090 inch). Test all blades in this manner. WARNING: DO NOT ATTEMPT TO BEND OR STRAIGHTEN FAN BLADES IF NOT WITHIN SPECIFICATIONS. 4. Inspect fan assembly for cracks, bends, loose rivets or broken welds. Replace fan if any damage is found. CAUTION: If the fan blade assembly is replaced because of mechanical damage, the water pump and thermal viscous fan drive should also be inspected. These components could have been damaged due to excessive vibration. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Viscous Fan Drive - Service Procedures Fan Clutch: Technical Service Bulletins Viscous Fan Drive - Service Procedures NO: 07-09-98 GROUP: Cooling DATE: Dec. 18, 1998 SUBJECT: Viscous Fan Drive Service MODELS: 1998 - 1999 (AB) Ram Van 1998 - 1999 (AN) Dakota 1998 - 1999 (BR/BE) Ram Truck 1998 (ZJ) Grand Cherokee 1998 (ZG) Grand Cherokee (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L GASOLINE ENGINE BUILT AFTER JANUARY 5, 1998 (MDH 0105XX). DISCUSSION: Vehicles built after January 5, 1998 have the water pump pulley pressed onto the water pump hub shaft. As in previous models, the viscous fan drive is threaded onto the water pump hub shaft. Because the pulley is pressed onto the hub shaft, viscous fan drive removal/installation procedures are unique. The fan/viscous fan drive assembly can be removed or installed from the water pump by turning the mounting nut. To remove the fan/viscous fan drive assembly, turn the nut counterclockwise as viewed from the front. To install the fan/viscous fan drive assembly, turn the nut clockwise as viewed from the front. Threads on the viscous fan drive are RIGHT-HANDED. Snap-On 36 mm Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be used to remove/install the fan drive assembly on gasoline engines. To hold the water pump pulley from rotating, place Miller Special Tool 6958 Spanner Wrench onto the water pump pulley with adapter pins 8346 inserted into the holes on the pulley (Figure 1). NOTE: REPLACEMENT WATER PUMP P/N 53021018 HAS BEEN SUPERSEDED TO P/N 53021018AB WHICH WILL HAVE THE PULLEY PRESSED ONTO THE WATER PUMP HUB SHAFT. WATER PUMP P/N 53021018 WAS USED TO SERVICE 1993 - 1998 3.9L/5.2L/5.9L (GASOLINE ENGINES) WATER PUMPS. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Viscous Fan Drive - Service Procedures > Page 1721 Fan Clutch: Technical Service Bulletins Engine Cooling Fan - Roaring Noise Explanation NO: 07-05-98 GROUP: Cooling DATE: Sep. 4, 1998 SUBJECT: Engine Cooling Fan Noise MODELS: 1998 - 1999 (AB) Ram Van/Wagon 1997 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: Some vehicles may exhibit an engine cooling fan "roar" noise. This noise is created by a large cooling fan that is required to provide optimum cooling for low vehicle speed operation in hot weather conditions and for heavy trailer towing. Since the large cooling fan is unnecessary in most operating conditions, these vehicles are also equipped with viscous fan drives that allow the fan to operate at variable speeds based upon temperature loads. The viscous fan drive will engage the fan for maximum cooling when temperatures are high and allow the fan to operate at slower speeds when temperatures are low. In addition, at engine start-up, the viscous fan drive engages the fan for maximum cooling until the fluid in the viscous clutch can dissipate out of the clutch drive grooves allowing the fan to operate at a slower speed. Because of the viscous fan drive, the noise may occur during high temperature conditions and for the first 1-2 minutes of operation. Due to the roar of the fan, customers may also complain of a perceived loss of power, automatic transmission slippage, or that the transmission is slaying into a low gear too long (delayed upshift). Customers concerned about this noise should be advised that this condition is normal and no repair attempts should be made. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 1722 Fan Clutch: Specifications Cooling Fan to Viscous Drive 200 in.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 1723 Fan Clutch: Description and Operation VISCOUS FAN DRIVE Fan Blade/Viscous Fan Drive Assembly Viscous Fan Drive-Typical The thermal viscous fan drive is a silicone-fluid- filled coupling used to connect the fan blades to the water pump shaft. The coupling allows the fan to be driven in a normal manner. This is done at low engine speeds while limiting the top speed of the fan to a predetermined maximum level at higher engine speeds. A thermostatic bi-metallic spring coil is located on the front face of the viscous fan drive unit (a typical viscous unit is shown in. This spring coil reacts to the temperature of the radiator discharge air. It engages the viscous fan drive for higher fan speed if the air temperature from the radiator rises above a certain point. Until additional engine cooling is necessary, the fan will remain at a reduced rpm regardless of engine speed. Only when sufficient heat is present, will the viscous fan drive engage. This is when the air flowing through the radiator core causes a reaction to the bimetallic coil. It then increases fan speed to provide the necessary additional engine cooling. Once the engine has cooled, the radiator discharge temperature will drop. The bimetallic coil again reacts and the fan speed is reduced to the previous disengaged speed. CAUTION: Engines equipped with serpentine drive belts have reverse rotating fans and viscous fan drives. They are marked with the word REVERSE to designate their usage. Installation of the wrong fan or viscous fan drive can result in engine overheating. CAUTION: If the viscous fan drive is replaced because of mechanical damage, the cooling fan blades should also be inspected. Inspect for fatigue cracks, loose blades, or loose rivets that could have resulted from excessive vibration. Replace fan blade assembly if any of these conditions are found. Also inspect water pump bearing and shaft assembly for any related damage due to a viscous fan drive malfunction. NOISE NOTE: It is normal for fan noise to be louder (roaring) when: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 1724 ^ The underhood temperature is above the engagement point for the viscous drive coupling. This may occur when ambient (outside air temperature) is very high. ^ Engine loads and temperatures are high such as when towing a trailer. ^ Cool silicone fluid within the fan drive unit is being redistributed back to its normal disengaged (warm) position. This can occur during the first 15 seconds to one minute after engine start-up on a cold engine. LEAKS Viscous fan drive operation is not affected by small oil stains near the drive bearing. If leakage appears excessive, replace the fan drive unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 1725 Fan Clutch: Testing and Inspection VISCOUS FAN DRIVE TESTING If the fan assembly free-wheels without drag (the fan blades will revolve more than five turns when spun by hand), replace the fan drive. This spin test must be performed when the engine is cool. For the following test, the cooling system must be in good condition. It also will ensure against excessively high coolant temperature. WARNING: BE SURE THAT THERE IS ADEQUATE FAN BLADE CLEARANCE BEFORE DRILLING. 1. Drill a 3.18-mm (1/8-in) diameter hole in the top center of the fan shroud. 2. Obtain a dial thermometer with an 8 inch stem (or equivalent). It should have a range of -18° to 105°C (0° to 220°F). Insert thermometer through the hole in the shroud. Be sure that there is adequate clearance from the fan blades. 3. Connect a tachometer and an engine ignition timing light (timing light is to be used as a strobe light). 4. Block the air flow through the radiator. Secure a sheet of plastic in front of the radiator (or air conditioner condenser). Use tape at the top to secure the plastic and be sure that the air flow is blocked. 5. Be sure that the air conditioner (if equipped) is turned off. WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING. 6. Start the engine and operate at 2400 rpm. Within ten minutes the air temperature (indicated on the dial thermometer) should be up to 88° C (190° F). Fan drive engagement should have started to occur at between 74° to 82° C (165° to 180° F). Engagement is distinguishable by a definite increase in fan flow noise (roaring). The timing light also will indicate an increase in the speed of the fan. 7. When the air temperature reaches 88° C (190° F), remove the plastic sheet. Fan drive disengagement should have started to occur at between 57° to 79° C (135° to 175° F). A definite decrease of fan flow noise (roaring) should be noticed. If not, replace the defective viscous fan drive unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 1726 Fan Clutch: Service and Repair VISCOUS FAN DRIVE Refer to Fan Blade for removal and installation procedures of the viscous drive unit. Viscous Fan Drive Fluid Pump Out Requirement: After installing a new viscous fan drive, bring the engine speed up to approximately 2000 rpm and hold for approximately two minutes. This will ensure proper fluid distribution within the drive. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls ECT Sensor Test revisions NUMBER: 26-11-97F GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L/4.0L/5.2L/5.9L SFI Engine Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revisions to the ECT sensor voltage too high test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions > Page 1732 165 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1733 Coolant Temperature Sensor/Switch (For Computer): Specifications Torque 11 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1734 Coolant Temperature Sensor/Switch (For Computer): Locations Generator, A/C Compressor, Elec.CONN, Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1735 Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1736 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Fig 1 Powertrain Control Module To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: 1. Vehicles equipped with air conditioning: a. Disconnect the negative battery cable at battery. b. Remove Jeep/Truck Engine Controller (JTEC) mounting bolts and remove JTEC. Do not disconnect three 32-way connectors from JTEC. Fig. 66 Engine Coolant Temperature Sensor 2. Disconnect wire harness connector from coolant temperature sensor. 3. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1737 Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 4. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 5. Test continuity of the wire harness between the JTEC wire harness connector and the coolant sensor connector terminals. - Refer to Diagrams/connector Views. - Repair the wire harness if an open circuit is indicated. 6. After tests are completed, connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1738 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING COOLANT TEMPERATURE SENSOR. Engine Coolant Temperature Sensor Location The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. 1. Disconnect negative battery cable at battery. 2. Place a small mirror above sensor connector. 3. Disconnect electrical connector from sensor. When removing connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place hook part of tool under connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Partially drain cooling system. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor into intake manifold. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. 5. Connect negative battery cable at battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Generator, A/C Compressor, Elec.CONN, Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications Fan Shroud: Specifications Fan Shroud to Radiator 50 in.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Heater Control Valve Cable > Component Information > Service and Repair Heater Control Valve Cable: Service and Repair The rear water valve control cable is used only on models with the optional rear heater-A/C unit. The rear water valve control cable can be removed without removing the rear heater-A/C unit from the vehicle. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect the control cable from the rear water valve. 3. Remove the rear mode control motor from the rear heater-A/C unit. Rear Water Valve Control Cable Remove/Install 4. Remove the screw that secures the rear water valve control cable flag retainer to the rear heater-A/C unit upper housing. 5. Remove the water valve control cable adaptor from the rear heat-A/C mode door pivot shaft. 6. Remove the rear water valve control cable and adaptor from the rear heater-A/C unit upper housing. 7. Separate the rear water valve control cable end from the hole on the end of the adaptor lever. INSTALLATION 1. Install the rear water valve control cable end into the hole on the end of the adaptor lever. 2. Position the rear water valve control cable and adaptor to the rear heater-A/C unit upper housing. 3. Install the rear water valve control cable adaptor into the rear heat-A/C mode door pivot shaft. Be certain to index the alignment splines on the adaptor to the spline in the pivot shaft. 4. Install the screw that secures the rear water valve control cable flag retainer to the rear heater-A/C unit upper housing. Tighten the mounting screw to 2.2 N.m (20 in. lbs.). 5. Reinstall the rear mode control motor onto the rear heater-A/C unit. 6. Connect the control cable to the rear water valve. 7. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation Heater Core: Description and Operation SYSTEM OPERATION Front The heater core is located in the heater-A/C housing, on the right side of the engine compartment. It is a heat exchanger made of rows of tubes and fins. Engine coolant is circulated through heater hoses to the heater core whenever the front water valve is open. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend air door allows control of the heater output air temperature by controlling how much of the air flowing through the heater-A/C housing is directed through or around the heater core. The blower motor speed controls the volume of air flowing through the heater-A/C system. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Rear Models equipped with the optional rear heater-A/C unit have a combination coil located within the rear unit housing. The combination coil functions as both the rear heater core and the rear evaporator coil. See Combination Coil in the Description and Operation for more information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 1752 Heater Core: Service and Repair Front REMOVAL 1. Remove the heater-A/C housing from the engine compartment. Refer to: "Housing Assembly HVAC : Service and Repair" See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair 2. Remove the top cover from the heater-A/C housing. Heater Core Remove/Install 3. Remove the screw that secures the heater core tube support bracket to the mounting boss on the top of the heater-A/C housing. 4. Lift the heater core out of the heater-A/C housing INSTALLATION 1. Insert the heater core into the bottom of the heater-A/C housing. 2. Install the screw that secures the heater core tube support bracket to the mounting boss on the top of the heater-A/C housing. Tighten the mounting screw to 2.2 N.m (20 in. lbs.). 3. Reinstall the top cover to the heater-A/C housing. 4. Reinstall the heater-A/C housing in the engine compartment. Rear The heater core for the optional rear heater-A/C unit is integral with the air conditioning evaporator coil. This unit is referred to as the combination coil. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Rear Heater-A/C Unit Plumbing Heater Hose: Service and Repair Rear Heater-A/C Unit Plumbing The rear heater-A/C unit plumbing is used only on models with the optional rear heater-A/C unit. while the formed metal rear heater-A/C unit suction line, liquid line, and heater lines are available for separate service replacement, the rear heater-A/C unit must be removed from the vehicle in order to service them. The molded and straight heater hoses used on the rear heater-A/C unit can be serviced in the vehicle. Any kinks or sharp bends in the rear heater-A/C unit plumbing will reduce the capacity of the entire heating and air conditioning system. Kinks and sharp bends reduce the system flow. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. High temperature coolant is present in the heater plumbing when the engine is operating. Extreme care must be exercised to make sure that each of the plumbing connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Remove the rear heater-A/C unit from the vehicle. 2. Disconnect the rear heater-A/C unit liquid and suction lines from the expansion valve. See Expansion Valve - Rear replacement procedures. 3. Disconnect the rear heater-A/C unit heater hoses from the heater inlet and outlet lines. Rear Heater-A/c Plumbing Remove/Install 4. Disengage the seal from the plumbing plate, which is secured to the forward outboard corner of the rear heater-A/C unit lower housing. Push the bottom of the seal out through the top of the plumbing plate from underneath. 5. Remove the plumbing lines and seal as an assembly from the rear heater-A/C unit. 6. If the suction line is being serviced, remove the tie-wraps that secure each end of the insulator to the line, then slide the insulator off. 7. Push the line through the hole from the top of the seal, twisting and turning the line as needed, while pulling it from the bottom of the seal. INSTALLATION 1. Push the line through the hole from the bottom of the seal, twisting and turning the line as needed, while pulling it from the top of the seal. 2. If the suction line is being serviced, slide the insulator onto the line, then secure each end of the insulator to the line with a tie-wrap. 3. Position the plumbing lines and seal as an assembly to the rear heater-A/C unit. 4. Reinstall the seal to the plumbing plate. Push the seal into the plumbing plate from the top until it is fully seated. 5. Connect the rear heater-A/C unit heater hoses to the heater inlet and outlet lines. 6. Connect the rear heater-A/C unit liquid and suction lines to the expansion valve. 7. Reinstall the rear heater-A/C unit in the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Rear Heater-A/C Unit Plumbing > Page 1757 Heater Hose: Service and Repair Underbody Plumbing The underbody plumbing lines are used only on models with the optional rear heater-A/C unit. While the underbody suction line, liquid line, and combination heater line are available for separate service replacement, all lines must be removed from the vehicle as a unit for service. Any kinks or sharp bends in the underbody plumbing will reduce the capacity of the entire heating and air conditioning system. Kinks and sharp bends reduce the system flow. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. High temperature coolant is present in the heater plumbing when the engine is operating. Extreme care must be exercised to make sure that each of the plumbing connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 4. From the engine compaftment, disconnect the underbody liquid line at the liquid line extension and the underbody suction line at the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. From the engine compaftment, disconnect the heater supply and return hoses from the underbody combination heater line. 6. Remove the engine cover from the passenger compaftment. 7. Raise and support the vehicle. 8. Disengage the front park brake release cable routing clip from the underbody suction line. Rear Heater-A/C Pluming Connections Remove/Install 9. From under the vehicle, disconnect the flare nut on the underbody liquid line from the threaded 10. From under the vehicle, disconnect the flare nut on the underbody suction line from the threaded fitting on the rear heater-A/C unit suction line. Install plugs in, or tape over all of the opened refrigerant line fittings. 11. From under the vehicle, disconnect the heater supply and return hoses from the rear heater-A/C unit heater lines. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Rear Heater-A/C Unit Plumbing > Page 1758 Underbody Plumbing Remove/Install 12. Remove the nut that secures the underbody plumbing clamp to the front floor panel near the left side of the engine cover opening. 13. Remove the screw that secures the underbody plumbing clamp to the front floor panel reinforcement. 14. Remove the screws that secure the two underbody refrigerant line clamps to the side panel to underbody reinforcement. 15. Remove the underbody plumbing bundle from the vehicle. INSTALLATION 1. From under the vehicle, position the underbody plumbing bundle to the side panel to underbody reinforcement and secure it by loosely installing the two clamp mounting screws. 2. From under the vehicle, connect the heater supply and return hoses to the rear heater-A/C unit heater lines. 3. From under the vehicle, remove the tape or plugs from the suction line fittings at the rear of the underbody plumbing bundle and at the rear heater-A/C unit. Connect the flare nut on the underbody suction line to the threaded fitting on the rear heater-A/C unit suction line. Tighten the fitting to 47 N.m 420 in. lbs. 4. From under the vehicle, remove the tape or plugs from the liquid line fittings at the rear of the underbody plumbing bundle and at the rear heaterA/C unit. Connect the flare nut on the underbody liquid line to the threaded fitting on the rear heaterA/C unit liquid line. Tighten the fitting to 27 N.m 244 in. lbs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Hose Clamp, Cooling System > Component Information > Specifications Hose Clamp: Specifications Hose Clamp (Worm Gear) 34 in.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation SYSTEM OPERATION The coolant temperature gauge gives an indication of the engine coolant temperature. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon engine coolant temperature messages received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the engine coolant temperature sensor and internal programming to decide what engine coolant temperature messages are required. The PCM then sends the proper messages to the instrument cluster on the CCD data bus. If the PCM messages indicate that coolant temperature is too high, the instrument cluster circuitry moves the gauge needle to the high end of the scale on the gauge face, turns on the Check Gauges lamp, and sends a chime tone request to the Central Timer Module (CTM). The engine coolant temperature sensor is installed in a threaded hole that penetrates a coolant passage of the engine. It is a thermistor-type sensor that changes its internal resistance with changes in engine coolant temperature. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 1766 Temperature Gauge: Testing and Inspection If the problem being diagnosed is related to coolant temperature gauge accuracy, be certain to confirm that the problem is with the gauge and not with cooling system performance. The actual engine coolant temperature should be checked with a test gauge or thermometer and compared to the instrument cluster coolant temperature gauge readings before you proceed with gauge diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Diagnosis of the coolant temperature sensor and circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For further diagnosis of the coolant temperature gauge and the instrument cluster circuitry, see Instrument Cluster in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation SYSTEM OPERATION Transmission Oil Temperature Warning Lamp The transmission oil temperature warning lamp gives an indication when the Powertrain Control Module (PCM) has detected that the automatic transmission oil is overheated. The lamp is controlled by the instrument cluster circuitry based upon messages received from the PCM on the Chrysler Collision Detection (CCD) data bus. The PCM sends lamp-on messages for about two seconds when the ignition switch is turned to the On position as a bulb test. Following the bulb test, the PCM uses an input from the automatic transmission oil temperature sensor located within the transmission, along with its internal programming, to decide whether a condition exists that requires the transmission oil temperature warning lamp to be turned on. The PCM then sends the proper messages to the instrument cluster on the CCD data bus to turn the lamp on or off. When the instrument cluster receives a message to turn the transmission oil temperature warning lamp on, it also sends a chime tone request to the Central Timer Module (CTM). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Page 1770 Temperature Warning Lamp/Indicator: Testing and Inspection Transmission Oil Temperature Warning Lamp The diagnosis found here addresses an inoperative transmission oil temperature warning lamp condition. If the transmission oil temperature warning lamp comes on and stays on with the engine running. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the transmission oil temperature warning lamp fails to light during the bulb test (about two seconds after the ignition switch is turned to the On position), diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For further diagnosis of the transmission oil temperature warning lamp and the instrument cluster circuitry, see Instrument Cluster in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair The radiator draincock is replaceable. Unscrew the draincock in a clockwise direction and remove from radiator. Install replacement draincock. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation Radiator Cap: Description and Operation Radiator Pressure Cap And Filler Neck-Typical Radiators are equipped with a pressure cap, which releases pressure at some point within a range of 97-138 kPa (14-20 psi). The pressure relief point (in pounds) is engraved on top of cap. The cooling system will operate at pressures slightly above atmospheric pressure. This results in a higher coolant boiling point allowing increased radiator cooling capacity. The cap contains a spring-loaded pressure relief valve that opens when system pressure reaches release range of 97-138 kPa (14-20 psi). A vent valve in the center of cap allows a small coolant flow through cap when coolant is below boiling temperature. The valve is completely closed when boiling point is reached. As the coolant cools, it contracts and creates a vacuum in the cooling system. This causes the vacuum valve to open and coolant in the reserve/overflow tank to be drawn through its connecting hose into radiator. If the vacuum valve is stuck shut, the radiator hoses will collapse on cool down. Clean the vent valve. A rubber gasket seals radiator filler neck to prevent leakage. This is done to keep system under pressure. It also maintains vacuum during coolant cool-down allowing coolant to return from reserve/ overflow tank. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Radiator Cap - Pressure Testing Radiator Cap: Testing and Inspection Radiator Cap - Pressure Testing PRESSURE TESTING Pressure Testing Radiator Cap Remove cap from radiator. Be sure that sealing surfaces are clean. Moisten rubber gasket with water and install cap on pressure tester 7700 or an equivalent. Operate tester pump to bring pressure to 104 kPa (15 psi) on gauge. If pressure cap fails to hold pressure of at least 97 kPa (14 psi) replace cap. The pressure cap may test properly while positioned on tool 7700 (or equivalent). It may not hold pressure or vacuum when installed on radiator. If so, inspect radiator filler neck and cap's top gasket for damage. Also inspect for dirt or distortion that may prevent cap from sealing properly. CAUTION: Radiator pressure testing tools are very sensitive to small air leaks, which will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to tool. Turn tool upside down and recheck pressure cap to confirm that cap needs replacement. Radiator Pressure Cap And Filler Neck-Typical INSPECTION Hold cap at eye level, right side up. The vent valve at bottom of cap should open. If rubber gasket has swollen and prevents vent valve from opening, replace cap. Hold cap at eye level, upside down. If any light can be seen between vent valve and rubber gasket, replace cap. Do not use a replacement cap that has a spring to hold vent shut. A replacement cap must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow coolant return to radiator. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Radiator Cap - Pressure Testing > Page 1780 Radiator Cap: Testing and Inspection Radiator Cap to Filler Neck Seal - Pressure Relief Check RADIATOR CAP-TO-FILLER NECK SEAL PRESSURE RELIEF CHECK The pressure cap upper gasket (seal) pressure relief can be tested by removing overflow hose from radiator filler neck nipple. Attach hose of pressure tester tool 7700 (or equivalent) to nipple. It will be necessary to disconnect hose from its adapter for filler neck. Pump air into radiator. The pressure cap upper gasket should relieve at 69-138 kPa (10-20psi) and hold pressure at a minimum of 55 kPa (8 psi). WARNING: THE WARNING WORDS (DO NOT OPEN HOT) ON RADIATOR PRESSURE CAP, ARE A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, RADIATOR CAP SHOULD NOT BE REMOVED WHILE SYSTEM IS HOT AND/OR UNDER PRESSURE. Do not remove radiator cap at any time except for the following purposes: ^ Check and adjust antifreeze freeze point ^ Refill system with new antifreeze ^ Conducting service procedures ^ Checking for vacuum leaks WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT AT LEAST 15 MINUTES BEFORE REMOVING RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR UPPER HOSE TO CHECK IF SYSTEM IS UNDER PRESSURE. PLACE A RAG OVER CAP AND WITHOUT PUSHING CAP DOWN, ROTATE IT COUNTERCLOCKWISE TO FIRST STOP. ALLOW FLUID TO ESCAPE THROUGH THE COOLANT RESERVE/OVERFLOW HOSE INTO RESERVE/OVERFLOW TANK. SQUEEZE RADIATOR UPPER HOSE TO DETERMINE WHEN PRESSURE HAS BEEN RELEASED. WHEN COOLANT AND STEAM STOP BEING PUSHED INTO TANK AND SYSTEM PRESSURE DROPS, REMOVE RADIATOR CAP COMPLETELY. RADIATOR CAP PRESSURE TESTING Pressure Testing Radiator Cap Remove cap from radiator. Be sure that sealing surfaces are clean. Moisten rubber gasket with water and install cap on pressure tester 7700 or an equivalent. Operate tester pump to bring pressure to 104 kPa (15 psi) on gauge. If pressure cap fails to hold pressure of at least 97 kPa (14 psi) replace cap. The pressure cap may test properly while positioned on tool 7700 (or equivalent). It may not hold pressure or vacuum when installed on radiator. If so, inspect radiator filler neck and cap's top gasket for damage. Also inspect for dirt or distortion that may prevent cap from sealing properly. CAUTION: Radiator pressure testing tools are very sensitive to small air leaks, which will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to tool. Turn tool upside down and recheck pressure cap to confirm that cap needs replacement. INSPECTION Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Radiator Cap - Pressure Testing > Page 1781 Radiator Pressure Cap And Filler Neck-Typical Hold cap at eye level, right side up. The vent valve at bottom of cap should open. If rubber gasket has swollen and prevents vent valve from opening, replace cap. Hold cap at eye level, upside down. If any light can be seen between vent valve and rubber gasket, replace cap. Do not use a replacement cap that has a spring to hold vent shut. A replacement cap must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow coolant return to radiator. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls ECT Sensor Test revisions NUMBER: 26-11-97F GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L/4.0L/5.2L/5.9L SFI Engine Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revisions to the ECT sensor voltage too high test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions > Page 1788 165 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1789 Coolant Temperature Sensor/Switch (For Computer): Specifications Torque 11 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1790 Coolant Temperature Sensor/Switch (For Computer): Locations Generator, A/C Compressor, Elec.CONN, Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1791 Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1792 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Fig 1 Powertrain Control Module To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: 1. Vehicles equipped with air conditioning: a. Disconnect the negative battery cable at battery. b. Remove Jeep/Truck Engine Controller (JTEC) mounting bolts and remove JTEC. Do not disconnect three 32-way connectors from JTEC. Fig. 66 Engine Coolant Temperature Sensor 2. Disconnect wire harness connector from coolant temperature sensor. 3. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1793 Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 4. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 5. Test continuity of the wire harness between the JTEC wire harness connector and the coolant sensor connector terminals. - Refer to Diagrams/connector Views. - Repair the wire harness if an open circuit is indicated. 6. After tests are completed, connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1794 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING COOLANT TEMPERATURE SENSOR. Engine Coolant Temperature Sensor Location The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. 1. Disconnect negative battery cable at battery. 2. Place a small mirror above sensor connector. 3. Disconnect electrical connector from sensor. When removing connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place hook part of tool under connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Partially drain cooling system. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor into intake manifold. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. 5. Connect negative battery cable at battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Generator, A/C Compressor, Elec.CONN, Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation SYSTEM OPERATION The coolant temperature gauge gives an indication of the engine coolant temperature. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon engine coolant temperature messages received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the engine coolant temperature sensor and internal programming to decide what engine coolant temperature messages are required. The PCM then sends the proper messages to the instrument cluster on the CCD data bus. If the PCM messages indicate that coolant temperature is too high, the instrument cluster circuitry moves the gauge needle to the high end of the scale on the gauge face, turns on the Check Gauges lamp, and sends a chime tone request to the Central Timer Module (CTM). The engine coolant temperature sensor is installed in a threaded hole that penetrates a coolant passage of the engine. It is a thermistor-type sensor that changes its internal resistance with changes in engine coolant temperature. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 1801 Temperature Gauge: Testing and Inspection If the problem being diagnosed is related to coolant temperature gauge accuracy, be certain to confirm that the problem is with the gauge and not with cooling system performance. The actual engine coolant temperature should be checked with a test gauge or thermometer and compared to the instrument cluster coolant temperature gauge readings before you proceed with gauge diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Diagnosis of the coolant temperature sensor and circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For further diagnosis of the coolant temperature gauge and the instrument cluster circuitry, see Instrument Cluster in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation SYSTEM OPERATION Transmission Oil Temperature Warning Lamp The transmission oil temperature warning lamp gives an indication when the Powertrain Control Module (PCM) has detected that the automatic transmission oil is overheated. The lamp is controlled by the instrument cluster circuitry based upon messages received from the PCM on the Chrysler Collision Detection (CCD) data bus. The PCM sends lamp-on messages for about two seconds when the ignition switch is turned to the On position as a bulb test. Following the bulb test, the PCM uses an input from the automatic transmission oil temperature sensor located within the transmission, along with its internal programming, to decide whether a condition exists that requires the transmission oil temperature warning lamp to be turned on. The PCM then sends the proper messages to the instrument cluster on the CCD data bus to turn the lamp on or off. When the instrument cluster receives a message to turn the transmission oil temperature warning lamp on, it also sends a chime tone request to the Central Timer Module (CTM). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Page 1805 Temperature Warning Lamp/Indicator: Testing and Inspection Transmission Oil Temperature Warning Lamp The diagnosis found here addresses an inoperative transmission oil temperature warning lamp condition. If the transmission oil temperature warning lamp comes on and stays on with the engine running. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the transmission oil temperature warning lamp fails to light during the bulb test (about two seconds after the ignition switch is turned to the On position), diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For further diagnosis of the transmission oil temperature warning lamp and the instrument cluster circuitry, see Instrument Cluster in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications THERMOSTAT TEMPERATURE OPERATING RANGE: INFORMATION NOT SUPPLIED BY THE MANUFACTURER. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1809 Thermostat: Description and Operation Thermostats installed in the 3.9L/5.2L/5.9L engines are of the wax- pellet-driven, reverse-poppet-choke-type. The wax pellet is located in a sealed container at spring end of thermostat. When heated, the pellet expands, overcoming closing spring tension and water pump pressure to force valve to open. Coolant leakage into pellet container will cause thermostat to fail in open position. Do not attempt to free a sticking thermostat with a prying device. The thermostat controls the operating temperature of the engine by controlling the amount of coolant flow to radiator. On all engines, the thermostat is closed below 88°C (192°F). When coolant reaches this temperature, thermostat begins to open allowing coolant flow to radiator. This provides quick engine warm-up and overall temperature control. The thermostat is designed to provide a minimum engine operating temperature range of from 88 to 93°C (192 to 199°F). The thermostat should be fully open for maximum coolant flow during operation in hot ambient temperatures of approximately 104°C (220°F). Above 104°C (220°F), coolant temperature is controlled by radiator, fan and ambient temperature. An arrow, plus the word UP is stamped on front flange next to air bleed. The words TO RAD are stamped on one arm of thermostat. They indicate proper installed position. The same thermostat is used for winter and summer seasons. CAUTION: Do not operate an engine without a thermostat, except for servicing or testing. An engine should not be operated without a thermostat, except for servicing or testing. Operating without a thermostat causes longer engine warm-up time, unreliable warm-up performance, increased exhaust emissions and crankcase condensation that can result in sludge formation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1810 Thermostat: Service and Repair REMOVAL WARNING: DO NOT LOOSEN THE RADIATOR DRAINCOCK OR CAP WITH THE SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM THE COOLANT CAN OCCUR. Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse. If the thermostat is being replaced, be sure that the replacement is the specified thermostat for the vehicle model and engine type. Factory installed thermostat housings on all engines are installed on a gasket with an anti-stick coating. This will aid in gasket removal and clean-up. 1. Disconnect negative battery cable at battery. 2. Drain cooling system until coolant level is below thermostat. 3. If equipped with air conditioning: a. Remove engine cover from vehicle interior. Generator Support Bracket b. Remove the support bracket (generator mounting bracket-to-intake manifold) located near the rear of generator. Automatic Belt Tensioner-Belt Removal/Installation c. The generator must be partially removed. Drive belts on all engines are equipped with a spring loaded automatic belt tensioner. Remove the generator drive belt as follows: d. Attach a socket/wrench to the pulley mounting bolt of the automatic tensioner. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1811 e. Rotate the tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. f. Remove belt from generator pulley. g. Remove the two generator mounting bolts. Do not remove any wiring at generator. h. Remove generator. Position generator to gain access for thermostat gasket removal. PCM Location i. Remove the three powertrain control module (PCM) mounting bolts and remove PCM. Do not disconnect 60-way connector from PCM. Lay PCM aside. Hose Clamp Tool-Typical WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1812 Clamp Number/Letter Location CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 4. Remove upper radiator hose clamp. Remove upper radiator hose at thermostat housing. 5. Position the wiring harness (behind the thermostat housing) to gain access to thermostat housing. Thermostat-Typical 6. Remove thermostat housing mounting bolts, thermostat housing, gasket and thermostat. Discard old gasket. INSTALLATION 1. Clean mating areas of intake manifold and thermostat housing. 2. Install thermostat (spring side down) into recessed machined groove on intake manifold. 3. Install gasket on intake manifold and over thermostat. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1813 Thermostat Position 4. Position the thermostat housing to the intake manifold. Note the word FRONT stamped on the housing. For adequate clearance, this must be placed towards the front of vehicle. The housing should be slightly angled forward after installation to intake manifold. 5. Install two housing-to-intake manifold bolts. Tighten bolts to 23 Nm (200 inch lbs.) torque. CAUTION: Housing must be tightened evenly and thermostat must be centered into recessed groove in intake manifold. If not, it may result in a cracked housing, damaged intake manifold threads or coolant leak. 6. Install upper radiator hose to thermostat housing. 7. Air conditioned vehicles: a. Install generator. Tighten bolts to 41 Nm (30 ft. lbs.). b. Install support bracket (generator mounting bracket-to-intake manifold). Tighten bolts to 54 Nm (40 ft. lbs.) torque. Accessory Drive Belt Routing-All Engines CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction. Refer to Engine, Drive Belts, Mounts, Brackets and Accessories, d Drive Belt for correct engine belt routing. The correct belt with the correct length must be used. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1814 c. Position the drive belt over all pulleys except the idler pulley (located between the generator and A/C compressor). d. Attach a socket/wrench to the pulley mounting bolt of the automatic tensioner. e. Rotate the socket/wrench clockwise. Place the belt over the idler pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly seated on all pulleys. f. Install PCM. The following belt routing schematics are published from the latest information available at the time of publication. If anything differs between these schematics and the Belt Routing Label, use the schematics on Belt Routing Label. This label is located in the engine compartment. 8. Fill cooling system. 9. Connect battery negative cable. 10. Start and warm engine. Check for leaks. 11. Install engine cover (if A/C equipped). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Thermostat Housing 225 in.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Mounting Bolts 30 ft.lb Water Pump Pulley 16 ft.lb Water Pump-to-Chain Case Cover Bolt 31 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1821 Water Pump: Description and Operation A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in a bearing pressed into the water pump body. The body has a small hole for ventilation. The water pump seals are lubricated by antifreeze in the coolant mixture. Additional lubrication is not necessary. A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core. The water pump on all models can be removed without discharging the air conditioning system (if equipped). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Pump Replacement Water Pump: Service and Repair Water Pump Replacement REMOVAL The water pump on all engines is bolted directly to the engine timing chain case/cover. A gasket is used as a seal between the water pump and timing chain case/cover. If water pump is replaced because of bearing/shaft damage or leaking shaft seal, the mechanical cooling fan assembly should also be inspected. Inspect for fatigue cracks, loose blades or loose rivets that could have resulted from excessive vibration. Replace fan if any of these conditions are found. Also check condition of the thermal viscous fan drive. 1. Disconnect negative battery cable from battery. 2. Drain cooling system. 2. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. 3. Remove the plastic air cleaner intake tube. 4. Remove two-piece fan shroud. Remove lower half first. Hose Clamp Tool-Typical WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. Clamp Number/Letter Location CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 5. Remove upper radiator hose at radiator. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Pump Replacement > Page 1824 Fan Blade And Viscous Fan Drive-Typical 6. The thermal viscous fan drive is attached (threaded) to the water pump hub shaft. Remove the fan/fan drive assembly from water pump by turning the mounting nut counterclockwise (as viewed from front). Threads on the fan drive are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be used. Place a bar or screwdriver between the water pump pulley bolts to prevent the pulley from rotating. 7. If water pump is being replaced, do not unbolt fan blade assembly from the thermal viscous fan drive. 8. Remove fan blade/fan drive assembly from vehicle. 9. After removing fan blade/fan drive assembly, do not place the thermal viscous fan drive in the horizontal position. If stored horizontally, the silicone fluid in the viscous drive could drain into its bearing assembly and contaminate the bearing lubricant. 10. Do not remove the water pump pulley bolts at this time. Automatic Belt Tensioner-Typical 11. Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded automatic belt tensioner. Relax the tension from the belt by rotating the tensioner clockwise (as viewed from front). When all belt tension has been relaxed, remove accessory drive belt. 12. Remove the four water pump pulley-to-water pump hub bolts and remove pulley from engine. 13. Remove the lower radiator hose at water pump. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Pump Replacement > Page 1825 Coolant Return Tube-Typical 14. Loosen heater hose coolant return tube mounting bolt and remove tube from water pump. Discard the old tube O-ring. 15. Remove the seven water pump mounting bolts. 16. Loosen the clamp at the water pump end of bypass hose. Slip the bypass hose from the water pump while removing pump from engine. Do not remove the clamp from the bypass hose. 17. Discard old gasket. CAUTION: Do not pry the water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks. INSTALLATION Water Pump Bolts-Typical 1. Clean gasket mating surfaces. 2. Using a new gasket, install water pump to engine as follows: Guide water pump fitting into bypass hose as pump is being installed. Install water pump mounting bolts. Tighten bolts in a criss-cross pattern to 40 Nm (30 ft. lbs.) torque. 3. Position bypass hose clamp to bypass hose. 4. Spin water pump to be sure that pump impeller does not rub against timing chain case/cover. 5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation. 6. Install coolant return tube and its mounting bolt to engine. Be sure the slot in tube bracket is bottomed to mounting bolt. This will properly position return tube. 7. Connect radiator lower hose to water pump. 8. Connect heater hose and hose clamp to coolant return tube. 9. Install water pump pulley. Tighten bolts to 27 Nm (20 ft. lbs.) torque. Place a bar or screwdriver between water pump pulley bolts to prevent pulley from rotating. 10. Relax tension from automatic belt tensioner. Install drive belt. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Pump Replacement > Page 1826 Belt Routing-All Engines CAUTION: When installing the serpentine accessory drive belt, belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to the Belt Routing Label for correct belt routing. The correct belt with correct length must be used. The provided belt routing schematics are published from the latest information available at the time of publication. If anything differs between these schematics and the Belt Routing Label, use the schematics on Belt Routing Label. This label is located in the engine compartment. 11. Install the fan blade/viscous fan drive assembly to water pump shaft. 12. Install fan shroud. 13. Install plastic air cleaner intake tube. 14. Install upper radiator hose and hose clamp to radiator. 15. Fill cooling system. 16. Connect negative battery cable. 17. Start and warm the engine. Check for leaks. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Pump Replacement > Page 1827 Water Pump: Service and Repair Cleaning and Inspection Replace water pump assembly if it has any of the following conditions: ^ The body is cracked or damaged ^ Water leaks from the shaft seal. This is evident by traces of coolant below the vent hole ^ Loose or rough turning bearing. Also inspect thermal viscous fan drive ^ Impeller rubs either the pump body or timing chain case/cover Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service Precautions > Customer Safety Information Catalytic Converter: Customer Safety Information CATALYTIC CONVERTER The catalytic converter routinely reaches operating temperatures of 650° C (1200° F) and will stay hot for some time after the engine has been shut off. Do NOT park the vehicle over any object or material that could ignite (i.e. dry leaves, cardboard, puddles of oil, or other combustibles). CARBON MONOXIDE Exhaust gas contains toxic carbon monoxide. Do not run the engine in confined areas or breathe concentrated exhaust gases. Breathing exhaust gases may cause loss of consciousness or death. EXHAUST SYSTEM LEAKS Repair any leaks in the exhaust system as soon as possible. Hot gases escaping from the leak can ignite flammable materials and may set the vehicle on fire. Also exhaust may circulate through the passenger compartment causing throat, sinus, and eye irritation, light headedness, headaches, and increased irritability, especially while driving with windows closed. FUEL ODORS/EXCESSIVE EMISSIONS Be alert for fuel odors and excessive tailpipe emissions (black smoke etc...). These indicate a problem that should be corrected as soon as possible (excessive emissions can ruin oxygen sensors, catalytic converters, and other expensive emission components). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service Precautions > Customer Safety Information > Page 1833 Catalytic Converter: Technician Safety Information WHEN SERVICING ANY VEHICLE OBSERVE THE FOLLOWING CAUTIONS: 1. Always wear appropriate eye protection. 2. Block the drive wheels as a safety routine before beginning any service with the vehicle on the ground. 3. Never work under a vehicle supported only by a jack. Use jackstands on a flat and level hard surface for safe support. 4. Use caution when working near the catalytic converter to prevent the possibility of burns. The temperatures within the converter can exceed 1200°F. 5. Exercise care when working with spring or tension loaded fasteners such as E-clips, or snap rings, careless removal can cause personal injury. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service Precautions > Customer Safety Information > Page 1834 Catalytic Converter: Vehicle Damage Warnings CATALYTIC CONVERTERS On vehicles equipped with catalytic converters, the following conditions must be observed: - Use only "UNLEADED FUEL". - Avoid running out of fuel. - In case of poor engine operation (misfiring), avoid driving the vehicle and correct the problem as soon as possible. - Do not disconnect any spark plug wires with the engine running. - Avoid push starting the vehicle. - If running on a dynamometer, make sure the catalytic converter is well ventilated. - Use caution when working near the catalytic converter to prevent the possibility of burns. OXYGEN SENSORS AND SILICONE Do not use silicone based products on an oxygen sensor equipped vehicle to avoid damaging the sensor. COMPRESSION TESTING When performing a compression test, remove the fuel pump relay fuse, and disconnect power to the ignition (This will stop fuel flow to the injectors and prevent engine from starting). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service Precautions > Page 1835 Catalytic Converter: Description and Operation CONSTRUCTION The stainless steel catalytic converter body is designed to last the life of the vehicle. HEAT Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also, inspect all other components of the exhaust system for heat damage. CAUTION: Unleaded gasoline must be used to avoid contaminating the catalyst core. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Removal and Installation Catalytic Converter: Service and Repair Removal and Installation CATALYTIC CONVERTER WITH PIPES REMOVAL 1. Raise and support vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove clamps and nuts. 4. Remove the catalytic converter. INSTALLATION 1. Assemble converter and clamps loosely in place. 2. Install the exhaust pipe onto exhaust manifolds, tighten 34 Nm (25 ft. lbs.). 3. Tighten all clamp nuts to 43 Nm (32 ft. lbs.) torque. 4. Lower the vehicle. 5. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. A minimum of 25.4 mm (1.0 in.) is required between exhaust system components and body/frame parts. Adjust the alignment, if needed. CLEANING Clean ends of pipes and muffler to assure a good seal at mating surfaces. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Removal and Installation > Page 1838 Catalytic Converter: Service and Repair Cleaning and Inspection CATALYTIC CONVERTER INSPECTION Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of overheating. If the converter has a heat shield attached make sure it is not bent or loose. WARNING: UNLEADED FUEL MUST BE USED TO PREVENT BLOCKAGE OR CONTAMINATION TO THE CATALYST CORE. If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate a damaged core. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications To Head Bolts/Nuts ............................................................................................................................. ..................................................... 34 Nm (25 ft. lbs.) To Exhaust Pipe ............................................... ......................................................................................................................................... 26 Nm (19 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1842 Exhaust Manifold: Description and Operation The exhaust manifolds are constructed of cast iron and are LOG type with balanced flow. Engine exhaust manifolds are constructed with porting for air injection into the LOG. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation Exhaust Manifold: Service and Repair Removal and Installation REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise and support the vehicle. 3. Remove the bolts and nuts attaching the exhaust pipe to the engine exhaust manifold. 4. Lower the vehicle. 5. Remove the engine cover. Engine Heat Shield-Left Side 6. Remove the exhaust heat shields. 7. Remove bolts, nuts and washers attaching manifold to cylinder head. 8. Remove manifold from the cylinder head. INSTALLATION CAUTION: If the studs came out with the nuts when removing the engine exhaust manifold, install new studs. Apply sealer on the coarse thread ends.. Water leaks may develop at the studs if this precaution is not taken. Engine Exhaust Manifold Installation - V-6 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1845 Engine Exhaust Manifold Installation - V-8 1. Position the engine exhaust manifolds on the two studs located on the cylinder head. Install conical washers and nuts on these studs. 2. Install two bolts and conical washers at the inner ends of the engine exhaust manifold outboard. arms. Install two bolts WITHOUT washers on the center arm of engine exhaust manifold. Starting at the center arm and working outward, tighten the bolts and nuts to 34 Nm (25 ft. lbs.) torque. 3. Install the exhaust heat shields. Tighten the screws to 6 Nm (55 inch lbs.) torque. 4. Install the engine cover. 5. Raise and support the vehicle. 6. Assemble exhaust pipe to manifold and secure with bolts, nuts and retainers. Tighten the bolts and nuts to 26 Nm (19 ft. lbs.) torque. 7. Lower the vehicle. 8. Connect the negative cable to the battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1846 Exhaust Manifold: Service and Repair Cleaning and Inspection CLEANING Clean mating surfaces on cylinder head and manifold. Wash with solvent and blow dry with compressed air. INSPECTION Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness with a straight edge. Gasket surfaces must be flat within 0.2 mm per 300 mm (0.008 inch per foot). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Exhaust Pipe - to - Exhaust Manifold 25 ft.lb Ehaust Clamps (All) Nuts 32 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 1850 Exhaust Pipe: Service and Repair TAILPIPE WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, WEAR PROTECTIVE EYE COVERING AND DO NOT ALLOW THE FLAME NEAR THE FUEL LINES. CAUTION: When servicing or replacing exhaust system components, be sure to disconnect all oxygen sensor connectors. Allowing the exhaust system to hang by the harness will damage the wiring and/or sensor. REMOVAL 1. Disconnect battery negative cable. 2. Raise and support the vehicle. 3. Remove the tailpipe hanger rods from the front and rear mount insulators. 4. Remove the tailpipe to muffler exhaust clamp. 5. Heat the muffler to tailpipe connection with an oxygen/acetylene torch. 6. Remove the tailpipe. INSTALLATION 1. Clean ends of pipes and muffler to assure mating of all parts. 2. Position the tailpipe into the muffler. Install the nuts onto the clamp bolt finger tight. 3. Insert the tailpipe hanger rods into the insulators. 4. Verify exhaust system alignment and tighten the muffler rear clamp nuts to 43 Nm (32 ft. lbs.) torque. 5. Lower the vehicle. 6. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Specifications Exhaust Pipe/Muffler Hanger: Specifications Tailpipe Hanger (Front) Bolts 30 in.lb Tailpipe Hanger (Rear) Bolt 170 in.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Heat Shields (All) Bolts/Nuts 100 in.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1857 Heat Shield: Description and Operation Exhaust heat shields are needed to protect both the vehicle and the environment from the high temperatures developed by the catalytic converter. The combustion reaction facilitated by the catalyst releases additional heat in the exhaust system. Under severe operating conditions, the temperature increases in the area of the reactor. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. DO NOT remove spark plug wires from plugs or by any other means short out cylinders. Failure of the catalytic converter can occur due to a temperature increase caused by unburned fuel passing through the converter. Do not allow the engine to operate at fast idle for extended periods (over 5 minutes). This condition may result in excessive temperatures in the exhaust system and on the floor pan. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1858 Heat Shield: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the nuts or bolts holding the exhaust heat shield to the floor pan, crossmember or bracket. 3. Slide the shield out around the exhaust system. INSTALLATION 1. Position the exhaust heat shield to the floor pan, crossmember or bracket and install the nuts or bolts. 2. Tighten the nuts or bolts to 11 Nm (100 inch lbs.). 3. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, WEAR PROTECTIVE EYE COVERING AND DO NOT ALLOW THE FLAME NEAR THE FUEL LINES. CAUTION: When servicing or replacing exhaust system components, be sure to disconnect all oxygen sensor connectors. Allowing the exhaust system to hang by the harness will damage the wiring and/or sensor. REMOVAL 1. Disconnect battery negative cable. 2. Raise and support the vehicle. 3. Remove tailpipe front and rear hanger rods from their insulators. 4. Remove muffler to converter and muffler to tailpipe exhaust clamps. 5. Heat muffler to tailpipe connection with an oxygen/acetylene torch. Twist tailpipe off of muffler. 6. Heat muffler to converter connection with an oxygen/acetylene torch. Twist muffler off of converter pipe. 7. Remove muffler from vehicle. INSTALLATION 1. Install the muffler into the catalytic converter flange pipe. Install the clamp and tighten the nuts by hand. 2. Install the tailpipe into the rear of the muffler. Install the clamp and tighten the nuts by hand. 3. Connect the tailpipe hanger rods to the insulators. 4. Verify exhaust system alignment and tighten both muffler clamp nuts to 43 Nm (32 ft. lbs.) torque. 5. Lower the vehicle. 6. Connect the battery negative cable. 7. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Module Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 1869 Central Timer Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1872 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1873 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1874 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1875 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1876 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1877 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1878 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1879 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1880 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1881 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1882 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1883 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1884 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1885 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1886 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1887 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1888 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1889 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1890 Body Control Module: Connector Views CTM Connector CTM Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1891 Body Control Module: Electrical Diagrams Central Timer Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1892 Vehicle Communications Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Central Timer Module Description Body Control Module: Description and Operation Central Timer Module Description The AB HIGH LINE utilize a Central Timer Module (CTM). The Base AB RAM VAN will not be addressed in this manual. For concerns about the Base AB VAN, please refer to the appropriate service and repair article. The CTM performs most of the typical functions a Body Control Module would perform. The CTM provides the following features: - Remote Keyless Entry (RKE) - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks WIRKE - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Vehicle Theft Security System (VTSS) The module is located on the left center instrument panel support. It contains a white 18-way and a green 14-way connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Central Timer Module Description > Page 1895 Body Control Module: Description and Operation System Description and Functional Operation The body system on the 1998 AB HIGH LINE consists of three modules that communicate over the CCD bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-Lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication. The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are performed through the Serial Communication Interface of SCI, the same as previous years. All of the information about the functioning of all the system is organized, controlled, and communicated by the CCD bus, which is described in Section 3 (CCD Bus) of this general information section. Through the CCD bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all the information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics Identification of Systems The vehicle Systems that are part of the "body" system are: - Airbag System (ACM) - Central Timer Module (CTM) - Instrument Cluster (MIC) - Vehicle Communication Diagnostic Strategies Diagnosis of the central timer module (CTM) is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem verification of proper operation Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM Technical Service Bulletin # 831 Date: 990601 Recall - Reprogram PCM June 1999 California Emissions Recall No. 831 Reprogram Powertrain Control Module Models 1998 (DN) Dodge Durango (with a 5.9L engine and automatic transmission) (AB) Dodge Ram Van/Wagon (with a 5.9L engine and automatic transmission) (ZJ) Jeep(R) Grand Cherokee (with a 5. 9L engine and automatic transmission) (AN) Dodge Dakota (with 5.2L engine and manual transmission or 5.9L engine and automatic transmission) (BR/BE)Dodge Ram Pickup (with a 5.2L engine and manual transmission, 5.9L engine and automatic transmission or 8.0L engine) NOTE: This recall applies only to certain vehicles equipped with a California emission control system (sales code NAE) built through April 30, 1998 (MDH 0430XX). Subject The On-Board Diagnostic (OBD) system on about 18,000 of the above vehicles may not detect evaporative emissions purge system malfunctions as required by California Emission Regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update labels and Authorized Modifications labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance PCM Update Previously Performed 08831181 0.2 hours Reprogram Powertrain Control Module 08831182 0.5 hours Add the cost of the labels plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 1906 Not Applicable Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD831". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure The DRB III(R) with either MDS1 or MDS2 is required to perform this repair. ^ If using the MDS1 and DRB III, the MDS must be operating at release 21 or higher and TIL CD release 1184 or higher must be installed. ^ If using the MDS2 and DRB III, the system must be operating at CIS CD2034 or higher. Using the MDS1 1. Connect the MDS1 (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 - CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU screen. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III UPDATE on the DRB III MAIN MENU. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER REPROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS1 AND DRB III on the MDS1, then press NEXT MENU. 7. FOLLOW THE STEPS PRESENTED ON THE MDS1 and DRB III that will allow the DRB III to obtain the current part number of the PCM. 8. The MDS1 will display the part number of the PCM on the vehicle and the appropriate replacement part number(s). Press NEXT MENU to begin programming. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 1907 9. The MDS and DRB III will prompt the operator for any action needed during the remainder of the programming process. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Step C. Using the MDS2 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. B. Install Authorized Software Update Label Fig. 1 Type or print (with a ballpoint pen) the necessary information on the "Authorized Software Update" label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Label Fig. 2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 1908 Type or print (with a ballpoint pen) the necessary information shown in Figure 2 onto the Authorized Modifications Label. Then attach the label near the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Owner Letter EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE Dear DaimlerChrysler Vehicle Owner: DaimlerChrysler has determined that some 1998 Dodge Dakota, Durango, Ram Van/Wagon, Ram Truck, and Jeep(R) Grand Cherokee vehicles, equipped with a V-8 or V-10 engine, may be in violation of California Emissions Regulations. The problem is... The On-Board Diagnostic (OBD) system on your vehicle (identified on the enclosed form) may not detect evaporative emissions purge system malfunctions as required by California Emissions Regulations. As a result, the OBD system on your vehicle may not illuminate the "Check Engine" light if the evaporative emissions purge system malfunctions. This could cause your vehicle to emit hydrocarbon levels above the limits that were established to protect the public health from the dangers of air pollution. Hydrocarbons (unburned fuel) combined with oxides of nitrogen, in the presence of sunlight, can cause the formation of ozone. These pollutants are the primary components of smog. What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will reprogram your vehicle's powertrain control module. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer right away to schedule a service appointment. ^ Bring the enclosed Owner Notification form with you to your dealer. It identifies the required service to the dealer. If you live in California and don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. How the state knows that the recall has been performed... State of California regulations require DaimlerChrysler to provide the Department of Motor Vehicles with a record of all vehicles that have not had the recall service performed. If you live in the state of California and your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. In order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. We are sorry for any inconvenience but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you for your attention to this important matter. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates Powertrain Control Module: All Technical Service Bulletins Engine Controls/Charging System Manual Updates NUMBER: 26-08-99F GROUP: Miscellaneous DATE: August, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998-2.5L, 3.9L, 5.2L, 5.9L, 8.0 SFI/Mechanically Injected Diesel Diagnostic Manual Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the Charging System Low Test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 1914 71 Revision to the 5.2/5.9L PCM Wiring Schematic Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 1915 744 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 > Recall - Reprogram PCM Technical Service Bulletin # 831 Date: 990601 Recall - Reprogram PCM June 1999 California Emissions Recall No. 831 Reprogram Powertrain Control Module Models 1998 (DN) Dodge Durango (with a 5.9L engine and automatic transmission) (AB) Dodge Ram Van/Wagon (with a 5.9L engine and automatic transmission) (ZJ) Jeep(R) Grand Cherokee (with a 5. 9L engine and automatic transmission) (AN) Dodge Dakota (with 5.2L engine and manual transmission or 5.9L engine and automatic transmission) (BR/BE)Dodge Ram Pickup (with a 5.2L engine and manual transmission, 5.9L engine and automatic transmission or 8.0L engine) NOTE: This recall applies only to certain vehicles equipped with a California emission control system (sales code NAE) built through April 30, 1998 (MDH 0430XX). Subject The On-Board Diagnostic (OBD) system on about 18,000 of the above vehicles may not detect evaporative emissions purge system malfunctions as required by California Emission Regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update labels and Authorized Modifications labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance PCM Update Previously Performed 08831181 0.2 hours Reprogram Powertrain Control Module 08831182 0.5 hours Add the cost of the labels plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 1920 Not Applicable Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD831". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure The DRB III(R) with either MDS1 or MDS2 is required to perform this repair. ^ If using the MDS1 and DRB III, the MDS must be operating at release 21 or higher and TIL CD release 1184 or higher must be installed. ^ If using the MDS2 and DRB III, the system must be operating at CIS CD2034 or higher. Using the MDS1 1. Connect the MDS1 (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 - CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU screen. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III UPDATE on the DRB III MAIN MENU. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER REPROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS1 AND DRB III on the MDS1, then press NEXT MENU. 7. FOLLOW THE STEPS PRESENTED ON THE MDS1 and DRB III that will allow the DRB III to obtain the current part number of the PCM. 8. The MDS1 will display the part number of the PCM on the vehicle and the appropriate replacement part number(s). Press NEXT MENU to begin programming. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 1921 9. The MDS and DRB III will prompt the operator for any action needed during the remainder of the programming process. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Step C. Using the MDS2 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. B. Install Authorized Software Update Label Fig. 1 Type or print (with a ballpoint pen) the necessary information on the "Authorized Software Update" label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Label Fig. 2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 1922 Type or print (with a ballpoint pen) the necessary information shown in Figure 2 onto the Authorized Modifications Label. Then attach the label near the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Owner Letter EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE Dear DaimlerChrysler Vehicle Owner: DaimlerChrysler has determined that some 1998 Dodge Dakota, Durango, Ram Van/Wagon, Ram Truck, and Jeep(R) Grand Cherokee vehicles, equipped with a V-8 or V-10 engine, may be in violation of California Emissions Regulations. The problem is... The On-Board Diagnostic (OBD) system on your vehicle (identified on the enclosed form) may not detect evaporative emissions purge system malfunctions as required by California Emissions Regulations. As a result, the OBD system on your vehicle may not illuminate the "Check Engine" light if the evaporative emissions purge system malfunctions. This could cause your vehicle to emit hydrocarbon levels above the limits that were established to protect the public health from the dangers of air pollution. Hydrocarbons (unburned fuel) combined with oxides of nitrogen, in the presence of sunlight, can cause the formation of ozone. These pollutants are the primary components of smog. What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will reprogram your vehicle's powertrain control module. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer right away to schedule a service appointment. ^ Bring the enclosed Owner Notification form with you to your dealer. It identifies the required service to the dealer. If you live in California and don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. How the state knows that the recall has been performed... State of California regulations require DaimlerChrysler to provide the Department of Motor Vehicles with a record of all vehicles that have not had the recall service performed. If you live in the state of California and your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. In order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. We are sorry for any inconvenience but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you for your attention to this important matter. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution Powertrain Control Module: All Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions Powertrain Control Module: All Technical Service Bulletins Engine Controls/Fuel System - Service Manual Revisions NUMBER: 26-12-97H GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L, 3.9L, 5.2L, 8.0L Powertrain Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the "No Cam Signal at PCM" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 1931 29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 1932 56 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 1933 58 Revision to the "Fuel Level Sending Unit" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 1934 412 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates Powertrain Control Module: All Technical Service Bulletins Engine Controls/Charging System Manual Updates NUMBER: 26-08-99F GROUP: Miscellaneous DATE: August, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998-2.5L, 3.9L, 5.2L, 5.9L, 8.0 SFI/Mechanically Injected Diesel Diagnostic Manual Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the Charging System Low Test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 1940 71 Revision to the 5.2/5.9L PCM Wiring Schematic Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 1941 744 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution Powertrain Control Module: All Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions Powertrain Control Module: All Technical Service Bulletins Engine Controls/Fuel System - Service Manual Revisions NUMBER: 26-12-97H GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L, 3.9L, 5.2L, 8.0L Powertrain Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the "No Cam Signal at PCM" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 1950 29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 1951 56 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 1952 58 Revision to the "Fuel Level Sending Unit" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 1953 412 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1954 Powertrain Control Module: Specifications Mounting Screws 1 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1955 Powertrain Control Module: Locations Fig 1 Powertrain Control Module The Powertrain Control Module (PCM) is located under the hood; mounted to the cowling, near the wiper motor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1958 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1959 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1960 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1961 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1962 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1963 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1964 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1965 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1966 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1967 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1968 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1969 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1970 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1971 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1972 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1973 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1974 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1975 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1976 Powertrain Control Module: Connector Views Powertrain Control Module Connectors Powertrain Control Module C1 - Black Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1977 C1 - Black C2 - White C2 - White C3 - Grey Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1978 C3 - Grey Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 1979 Powertrain Control Module: Description and Operation SYSTEM OPERATION Powertrain Control Module (PCM) The Powertrain Control Module (PCM) is located in the engine compartment. The ignition system is controlled by the PCM. NOTE: Base ignition timing by rotation of distributor is not adjustable. The PCM opens and closes the ignition coil ground circuit to operate the ignition coil. This is done to adjust ignition timing, both initial (base) and advance, and for changing engine operating conditions. The amount of electronic spark advance provided by the PCM is determined by five input factors: engine coolant temperature, engine rpm, intake manifold temperature, manifold absolute pressure and throttle position. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Module Replacement Powertrain Control Module: Service and Repair Module Replacement Fig 1 Powertrain Control Module REMOVAL 1. Disconnect the negative battery cable at battery. 2. Carefully unplug the three 32-way connectors from PCM. 3. Remove three Powertrain Control Module (PCM) mounting bolts and remove PCM from vehicle. INSTALLATION 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 4 N.m (35 in. lbs.). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary 4. Install three 32-way connectors. 5. Install battery cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Module Replacement > Page 1982 Powertrain Control Module: Service and Repair A Note About PCM Replacement Important Note: If the Powertrain Control Module has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS, Airbag and SKIM modules. In addition, if the vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. For ABS and Airbag Systems: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Airbag modules. For SKIM Theft Alarm: 1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. 3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM (this is required to allow the vehicle to start with the new PCM). 4. If three attempts are made to enter secured access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lock out mode, leave the ignition key in the Run/Start position for one hour. Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Auto Shutdown Relay Connector, Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1986 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1987 Auto Shutdown Relay Connector, Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1988 Automatic Shut Down (ASD) Relay: Description and Operation SYSTEM OPERATION As one of its functions, the (ASD) relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1989 Automatic Shut Down (ASD) Relay: Testing and Inspection Fig. 24 Asd And Fuel Pump Relay Terminals The relay terminal numbers can be found on the bottom of the relay: - Terminal number 30 is connected to battery voltage and can be switched or B+ (hot) at all times. - The center terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the component being operated. - Terminal number 86 is connected to a switched (+) power source. - Terminal number 85 is grounded by the Powertrain Control Module (PCM). TESTING 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. - Resistance value (ohms) should be 75 +/- 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. - Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. - Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). - Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. - Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. - Continuity should now be present between terminals number 87 and 30. - Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 volt power source. If continuity or resistance tests did not pass, replace relay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1990 Automatic Shut Down (ASD) Relay: Service and Repair Fig 2 Power Distribution Center The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC coven 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. - Also check the heights of relay terminal pins at PDC. - Pin height should be same for all pins. - Repair as necessary before installing relay. 2. Push the relay into the connector. 3. Install the relay cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Fuel Pump Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1995 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1996 Fuel Pump Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1997 Fuel Pump Relay: Service and Repair Fig 2 Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1998 Power Distribution Center -- Under The Hood, Near The Brake Master Cylinder The fuel pump and automatic shutdown (ASD) relays are located in the Power Distribution Center (PDC). The PDC is located in the engine compartment in front of the brake master cylinder. Refer to label on PDC cover for relay location. Check the terminals in the PDC relay connector for corrosion or damage before installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Auto Shutdown Relay Connector, Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2002 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2003 Auto Shutdown Relay Connector, Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2004 Automatic Shut Down (ASD) Relay: Description and Operation SYSTEM OPERATION As one of its functions, the (ASD) relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2005 Automatic Shut Down (ASD) Relay: Testing and Inspection Fig. 24 Asd And Fuel Pump Relay Terminals The relay terminal numbers can be found on the bottom of the relay: - Terminal number 30 is connected to battery voltage and can be switched or B+ (hot) at all times. - The center terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the component being operated. - Terminal number 86 is connected to a switched (+) power source. - Terminal number 85 is grounded by the Powertrain Control Module (PCM). TESTING 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. - Resistance value (ohms) should be 75 +/- 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. - Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. - Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). - Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. - Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. - Continuity should now be present between terminals number 87 and 30. - Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 volt power source. If continuity or resistance tests did not pass, replace relay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2006 Automatic Shut Down (ASD) Relay: Service and Repair Fig 2 Power Distribution Center The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC coven 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. - Also check the heights of relay terminal pins at PDC. - Pin height should be same for all pins. - Repair as necessary before installing relay. 2. Push the relay into the connector. 3. Install the relay cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Tray, Battery Tempt Sensor, Engine Wiring Harness, Sensor Harness Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2012 Battery Temperature Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2013 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2014 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry. refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pig-tail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 2017 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. Refer to Starting and Charging/Battery 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Refer to Starting and Charging/Battery Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2021 Camshaft Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2022 Camshaft Position Sensor: Description and Operation SYSTEM OPERATION The camshaft position sensor is located in the distributor on all engines. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2023 Camshaft Position Sensor: Testing and Inspection Camshaft Position Sensor - Typical The camshaft position sensor is located in the distributor on all engines. To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostics Procedures service. To test the sensor only, refer to the following: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Remove engine cover. 2. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. For wire identification. 3. Connect the negative (-) voltmeter lead into the ground wire. For wire identification. 4. Set the voltmeter to the 15 Volt DC scale. 5. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 6. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 7. If voltage is not present, check the voltmeter leads for a good connection. 8. If voltage is still not present, check for voltage at the supply wire. For wire identification. 9. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 10. If voltage is still not present, perform vehicle test using the DRB scan tool. 11. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM. If continuity is not present, repair the harness as necessary c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 12. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2024 Camshaft Position Sensor: Service and Repair The camshaft position sensor is located in the distributor. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove engine cover. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. Crankshaft Position Sensor 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls ECT Sensor Test revisions NUMBER: 26-11-97F GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L/4.0L/5.2L/5.9L SFI Engine Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revisions to the ECT sensor voltage too high test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions > Page 2029 165 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2030 Coolant Temperature Sensor/Switch (For Computer): Specifications Torque 11 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2031 Coolant Temperature Sensor/Switch (For Computer): Locations Generator, A/C Compressor, Elec.CONN, Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2032 Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2033 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Fig 1 Powertrain Control Module To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: 1. Vehicles equipped with air conditioning: a. Disconnect the negative battery cable at battery. b. Remove Jeep/Truck Engine Controller (JTEC) mounting bolts and remove JTEC. Do not disconnect three 32-way connectors from JTEC. Fig. 66 Engine Coolant Temperature Sensor 2. Disconnect wire harness connector from coolant temperature sensor. 3. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2034 Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 4. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 5. Test continuity of the wire harness between the JTEC wire harness connector and the coolant sensor connector terminals. - Refer to Diagrams/connector Views. - Repair the wire harness if an open circuit is indicated. 6. After tests are completed, connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2035 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING COOLANT TEMPERATURE SENSOR. Engine Coolant Temperature Sensor Location The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. 1. Disconnect negative battery cable at battery. 2. Place a small mirror above sensor connector. 3. Disconnect electrical connector from sensor. When removing connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place hook part of tool under connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Partially drain cooling system. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor into intake manifold. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. 5. Connect negative battery cable at battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Mounting Bolts 8 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2039 Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2040 Crankshaft Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2041 Crankshaft Position Sensor: Description and Operation SYSTEM OPERATION Sensor Operation Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. On this engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2042 Crankshaft Position Sensor: Testing and Inspection To perform a complete test of this sensor and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2043 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor - Typical The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. 1. Remove engine cover. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 N.m (70 in.lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications IAT Sensor IAT Sensor Torque 28 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2047 Intake Air Temperature Sensor: Locations Intake Manifold Air TEMPT Sensor, Electrical CONN Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2048 Intake Air TEMPT Sensor CONN Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2049 Intake Air Temperature Sensor: Testing and Inspection Fig. 69 Intake Manifold Air Temperature Sensor 1. Disconnect the wire harness connector from the intake manifold air temperature sensor. Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. Refer to the Coolant Temperature sensor/Intake Air Temperature sensor resistance chart. Replace the sensor if it is not within the range of resistance specified in the chart. 3. Test the resistance of the wire harness. Do this between the Powertrain Control Module (PCM) wire harness connector A-15 and the sensor connector terminal. Also check between PCM connector A-4 to the sensor connector terminal. Repair the wire harness as necessary if the resistance is greater than 1 ohm. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2050 Intake Air Temperature Sensor: Service and Repair Fig 57 Air Temperature Sensor REMOVAL 1. Disconnect electrical connector at sensor. 2. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 N.m (20 ft. lbs.) torque. 2. Install electrical connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Mounting Screws 3 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2054 Manifold Pressure/Vacuum Sensor: Locations Fig. 15 MAP And Throttle Position Sensor Location - Typical Map Sensor, Idle Air Control Motor, Throttle Position Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2055 Map Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2056 Manifold Pressure/Vacuum Sensor: Testing and Inspection Fig 57 Manifold Absolute Pressure Sensor 1. Inspect the rubber L-shaped fitting from the Manifold Absolute Pressure (MAP) sensor to the throttle body. Repair as necessary. CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. Fig 58 Rubber L-Shaped Fitting -- MAP Sensor-to-Throttle Body Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2057 Fig 33 MAP Sensor Connector Terminals -- Typical 2. Test the MAP sensor output voltage at the MAP sensor connector between terminals A and B. With the ignition switch ON and the engine OFF, output voltage should be 4-to-5 volts. The voltage should drop to 1.5-to-2.1 volts with a hot, neutral idle speed condition. 3. Test Powertrain Control Module (PCM) cavity A-27 for the same voltage described above to verify the wire harness condition. Repair as necessary. 4. Test MAP sensor supply voltage at sensor connector between terminals A and C with the ignition ON. The voltage should be approximately 5 volts (+/- 0.5V). Five volts (+/- 0.5V) should also be at cavity A-17 of the PCM wire harness connector. Repair or replace the wire harness as necessary 5. Test the MAP sensor ground circuit at sensor connector terminal-A and PCM connector A-4. Repair the wire harness if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2058 Manifold Pressure/Vacuum Sensor: Service and Repair Fig 86 MAP Sensor Location The Manifold Absolute Pressure (MAP) sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. NOTE: The throttle body must be removed from the intake manifold for MAP sensor removal. REMOVAL 1. Remove air cleaner assembly. 2. Remove throttle body. 3. Remove two MAP sensor mounting bolts (screws). 4. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body 5. Remove rubber L-shaped fitting from MAP sensor. Fig 87 MAP Sensor L-Shaped Rubber Fitting INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 N.m (25 in. lbs.) torque. 4. Install throttle body. 5. Install air cleaner. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions Oil Pressure Sensor: Technical Service Bulletins Engine Controls/Fuel System - Manual Revisions NUMBER: 26-01-99C GROUP: Miscellaneous DATE: January, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Powertrain 2.5L. 3.9L, 5.2L, 5.9L, 8.0 SFI, Mechanical Injected Diesel Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revision to the Table of Contents Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2063 vi Revision to the Trouble Code Test menu Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2064 538 Revision to the Oil Pressure Sensor test 589, 589A through 589F Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2065 589 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2066 589A Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2067 589B Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2068 589C Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2069 589D Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2070 589E Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2071 589F Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Torque 30 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2077 JTEC O2 Sensor Location Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2078 Oxygen Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2079 Oxygen Sensor: Application and ID Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2080 Oxygen Sensor: Testing and Inspection Fig 6 Heated Oxygen Sensors The upstream O2S sensor is located on the inlet end of the catalytic converter. The downstream O2S sensor is located on the outlet end of the catalytic converter. Each O2S heating element can be tested with an ohmmeter as follows: Disconnect the O2S sensor connector. Connect the ohmmeter test leads across the white wire terminals of the sensor connector. Resistance should be between 4 and 7 ohms. Replace the sensor if the ohmmeter displays an infinity (open) reading. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2081 Oxygen Sensor: Service and Repair Fig 6 Heated Oxygen Sensors NOTE: The O2S sensors are located at the inlet and outlet ends of the catalytic converter. WARNING: The exhaust manifold, exhaust pipes and catalytic converter become very hot during engine operation. Allow engine to cool before removing oxygen sensor. REMOVAL 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. NOTE: Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. INSTALLATION 1. Install the O2S sensor. Tighten to 30 N.m (22 ft. lbs.) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions Throttle Position Sensor: Technical Service Bulletins Fuel System/Engine Controls - Manual Revisions NUMBER: 26-02-99A GROUP: Miscellaneous DATE: February, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revision to the Diagnostic Trouble Codes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2086 45 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2087 46 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2088 47 Revision to the Throttle Position Sensor connector pin outs Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2089 152 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2090 156 Revision to the Fuel System Rich test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2091 316 Revisions to the Throttle Position sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2092 620 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2093 622 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2094 Throttle Position Sensor: Specifications Mounting Screws 7 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2095 Throttle Position Sensor: Locations Map Sensor Throttle Position Sensor, Idle Air Control Motor, Throttle Position Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2096 Throttle Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2097 Throttle Position Sensor: Testing and Inspection The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). - At idle, TPS output voltage should should be greater than 0.350 millivolts and less than 900 millivolts. - At wide open throttle, TPS output voltage must be less than 4.5 volts. - The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. NOTE: For additional testing information and circuit diagnosis see Computers and Control Systems/System Diagnosis/Procedures/Diagnostic Charts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2098 Throttle Position Sensor: Service and Repair Fig 80 TPS Mounting Bolts REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body Fig. 81 Installation INSTALLATION The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2102 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2107 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2108 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2109 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2110 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2111 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2112 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2113 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2114 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2115 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2116 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2117 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2118 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2119 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2120 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2121 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2122 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2123 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2124 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2125 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED AND DISTANCE-PCM INPUT The Vehicle Speed Sensor (VSS) is no longer used for any Dodge truck in the 1998 model year. Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for fuel system and speed control system operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > With Four Wheel Antilock Brakes Vehicle Speed Sensor: Service and Repair With Four Wheel Antilock Brakes REMOVAL 1. Raise and support vehicle. Rear Wheel Speed Sensor 2. Disconnect wire from rear sensor on axle housing. 3. Remove sensor and bracket mounting bolt and remove sensor and bracket. INSTALLATION 1. Secure sensor wire to rear brake hose with clips provided. 2. Install sensor and mounting bracket in axle housing. Install mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Connect wire to sensor and secure wire to mounting bracket. 4. Remove support and lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > With Four Wheel Antilock Brakes > Page 2128 Vehicle Speed Sensor: Service and Repair With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 0-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions Throttle Position Sensor: Technical Service Bulletins Fuel System/Engine Controls - Manual Revisions NUMBER: 26-02-99A GROUP: Miscellaneous DATE: February, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revision to the Diagnostic Trouble Codes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2134 45 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2135 46 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2136 47 Revision to the Throttle Position Sensor connector pin outs Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2137 152 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2138 156 Revision to the Fuel System Rich test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2139 316 Revisions to the Throttle Position sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2140 620 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2141 622 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2142 Throttle Position Sensor: Specifications Mounting Screws 7 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2143 Throttle Position Sensor: Locations Map Sensor Throttle Position Sensor, Idle Air Control Motor, Throttle Position Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2144 Throttle Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2145 Throttle Position Sensor: Testing and Inspection The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). - At idle, TPS output voltage should should be greater than 0.350 millivolts and less than 900 millivolts. - At wide open throttle, TPS output voltage must be less than 4.5 volts. - The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. NOTE: For additional testing information and circuit diagnosis see Computers and Control Systems/System Diagnosis/Procedures/Diagnostic Charts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2146 Throttle Position Sensor: Service and Repair Fig 80 TPS Mounting Bolts REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body Fig. 81 Installation INSTALLATION The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2151 Camshaft Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2152 Camshaft Position Sensor: Description and Operation SYSTEM OPERATION The camshaft position sensor is located in the distributor on all engines. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2153 Camshaft Position Sensor: Testing and Inspection Camshaft Position Sensor - Typical The camshaft position sensor is located in the distributor on all engines. To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostics Procedures service. To test the sensor only, refer to the following: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Remove engine cover. 2. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. For wire identification. 3. Connect the negative (-) voltmeter lead into the ground wire. For wire identification. 4. Set the voltmeter to the 15 Volt DC scale. 5. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 6. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 7. If voltage is not present, check the voltmeter leads for a good connection. 8. If voltage is still not present, check for voltage at the supply wire. For wire identification. 9. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 10. If voltage is still not present, perform vehicle test using the DRB scan tool. 11. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM. If continuity is not present, repair the harness as necessary c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 12. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2154 Camshaft Position Sensor: Service and Repair The camshaft position sensor is located in the distributor. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove engine cover. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. Crankshaft Position Sensor 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Mounting Bolts 8 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2158 Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2159 Crankshaft Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2160 Crankshaft Position Sensor: Description and Operation SYSTEM OPERATION Sensor Operation Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. On this engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2161 Crankshaft Position Sensor: Testing and Inspection To perform a complete test of this sensor and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2162 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor - Typical The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. 1. Remove engine cover. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 N.m (70 in.lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For electrical diagnosis of the Key-In-Switch, For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Replacement. On vehicles equipped with an automatic transmission and a steering column mounted shifter, an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. On vehicles equipped with an automatic transmission and a floor mounted shifter, a cable connects the interlock device within the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. The shifter interlock cable can be adjusted or replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 2167 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative battery cable from battery. 2. Place shifter in PARK position. 3. Remove tilt-wheel lever (pulls out). Lower Shroud Screws 4. Remove 2 lower shroud screws (size T25). Shroud Pivot Point 5. Upper and lower shrouds are snapped together at sides. Pivot points for lower and upper shrouds is at rear of shrouds. Lower shroud is hooked to pins on upper shroud. Tilt lower shroud down for removal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 2168 Upper Shroud Screws 6. Remove 2 upper shroud screws (size T5) and remove upper shroud from steering column. 7. If removing key lock cylinder only, proceed to next step. If removing ignition switch, proceed to IGNITION SWITCH REMOVAL. 8. KEY LOCK CYLINDER REMOVAL: Ignition key must be in key cylinder for cylinder removal. a. Rotate and hold key in START position. Lock Cylinder Retainer Pin Access Hole b. Position a 1/16" pin punch into lock cylinder retainer pin access hole. c. Press in on pin punch to release lock cylinder retainer pin while releasing key to RUN position. d. Pull lock cylinder out for removal. 9. IGNITION SWITCH REMOVAL: Key lock cylinder removal is not necessary for ignition switch removal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 2169 Installing Lock Cylinder To Column Removing/Installing Alarm Switch a. Remove alarm switch. Alarm switch is located at right/upper side of steering column. Press on retaining clip with a small screwdriver while rotating switch 1/4 turn for removal. b. Remove knee blocker below steering column. Refer to Knee Blocker in Instrument Panel Gauges And Warning Indicator. c. Note position of wiring harnesses and all tie wraps between ignition switch and 4 way connector at lower part of steering column. when installing ignition switch/wire harness assembly, the harnesses must be correctly routed with tie wraps in correct position to prevent damage to harness. d. If equipped with overdrive (OD) transmission, unclip OD wire harness at ignition switch. e. Cut necessary tie wraps. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 2170 Ignition Switch Mounting Screws f. Remove 2 ignition switch mounting screws (size T4) and separate switch at steering column. Separating 48-Way Connectors At Lower Part Of Column g. Separate steering column 48-way electrical connectors by removing one fastener (bolt). The 48-way connector is located near lower part of steering column. This 48-way connector contains 48 different pin-outs including 3 different connectors: a 17-way for the multi-function switch; a 13-way for the multi-function switch; and an 18-way for the ignition switch. Separating 48-Way Connectors At Lower Part Of Column h. Separate 17-way multi-function switch connector from 18-way ignition switch connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 2171 Steering Column 48-Way Connector (Male C0nnector To Column Shown) i. Separate 13-way multi-function switch connector from 18-way ignition switch connector. j. Separate multi-function switch wire harnesses from ignition switch wiring harness. k. Remove wiring harness and ignition switch as an assembly from steering column. INSTALLATION 1. KEY LOCK CYLINDER INSTALLATION: a. Place key into lock cylinder. b. Place key lock cylinder into steering column by aligning positioning tab on lock cylinder to positioning slot on steering column. Locking tab should also be aligned to locking tab slot. c. Press on lock cylinder until retaining pin engages. d. Rotate key to OFF position. e. Check for proper retention of lock cylinder by attempting to pull out on lock cylinder. 2. IGNITION SWITCH INSTALLATION: a. Position switch and wire harness assembly to steering column. b. Install switch screws and tighten to 1.4 N.m (12 in. lbs.) torque. c. Carefully route ignition switch wire harness down to bottom of steering column. d. If equipped with overdrive (OD) transmission, clip OD wire harness to ignition switch. e. Route alarm switch wire harness around ignition switch. f. Attach alarm switch to steering column by rotating and snapping into position). g. Attach 13-way multi-function switch connector to ignition switch 18-way connector. h. Attach 17-way multi-function switch connector to ignition switch 18-way connector. i. Attach both 48-way electrical connectors together (1 bolt). Tighten bolt to 7 N.m (62 in. lbs.) torque. j. Install new tie wraps in their previously noted positions. k. If equipped with a tilt steering wheel, operate tilt mechanism while observing wiring harnesses for binding. Correct binding if necessary. l. Operate shift lever while observing wiring harnesses for binding. Correct binding if necessary. 3. A 2-5/8" long plastic spacer is attached to inside of upper shroud. Before positioning shroud to column, verify spacer is tightened to upper shroud. 4. Position upper shroud to steering column. 5. Install 2 upper shroud screws. 6. Position rubber shields for shift lever and multi-function switch into upper shroud. 7. Position lower shroud hooks into pins on upper shroud. 8. Snap lower shroud to upper shroud. 9. Install 2 lower shroud screws. 10. Install tilt-wheel lever (snaps in). 11. Shifter should lock in PARK position when key is in LOCK position. Shifter should unlock when key rotated to ON position. 12. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 13. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify Steering wheel should unlock when key is rotated to ON position. 14. Connect negative battery cable to battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage NO: 14-03-98 GROUP: Fuel DATE: May 1, 1998 SUBJECT: Fuel Pressure Gauge Adapter Usage MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) DISCUSSION: Currently, four different fuel pressure adapters are required, depending on application, to attach a fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications Fuel Pressure: Pressure, Vacuum and Temperature Specifications Fuel Pressure Engine at curb idle ............................................................................................................................... ........................................ 339 ± 34 kPa (49.2 ± 5 psi) Pressure Leakdown (fuel pump not engaged) ................................................................................................................. Not fall below 30 psi for 5 minutes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2179 Fuel Pressure: Capacity Specifications NOTE: Before performing this test, verify fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. - Refer to the Fuel Pressure Release Procedure. 2. Disconnect the fuel supply line at fuel rail. - Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. - Insert other end of Adaptor Tool hose into a graduated container. 4. Remove the fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. - Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. - Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test Fig 9 Connecting Adaptor Tool -- Typical Fig. 8 Installing Adapter Tool And Pressure Gauge NOTE: Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: Fuel pressure bleeding past a fuel injector(s). - Fuel pressure bleeding past the check valve in the fuel pump module. 1. Disconnect the fuel inlet line at fuel rail. - On some engines, air cleaner housing removal may be necessary before fuel line disconnection. 2. Connect the appropriate Fuel Line Pressure Test Adapter Tool (number 6539, 6631, 6541 or 6923) between the disconnected fuel line and fuel rail (Fig. 9) or (Fig. 10). 3. Connect the 0-414 kPa (0-60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. - The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 4. Start engine and bring to normal operating temperature. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2182 5. Observe test gauge. Normal operating pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). 6. Shut engine off. 7. Pressure should not fall below 30 psi for five minutes. 8. If pressure falls below 30 psi, it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 9. Again, start engine and bring to normal operating temperature. 10. Shut engine off. 11. Testing for fuel injector or fuel rail leakage: - Clamp off the rubber hose portion of Adaptor Tool between the fuel rail and the test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a fuel injector or the fuel rail is leaking. 12. Testing for fuel pump check valve, filter/regulator check valve or fuel tube/line leakage: - Clamp off the rubber hose portion of Adaptor Tool between the vehicle fuel line and test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a leak may be found at a fuel tube/line. - If no leaks are found at fuel tubes or lines, one of the check valves in either the electric fuel pump or filter/ regulator may be leaking. NOTE: A quick loss of pressure usually indicates a defective check valve in the filter/regulator. A slow loss of pressure usually indicates a defective check valve in the electric fuel pump. The electric fuel pump is not serviced separately -- Replace the fuel pump module assembly. The filter/ regulator may be replaced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/installation for additional information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2183 Fuel Pressure: Testing and Inspection Fuel Pressure Test Fuel Pressure Test Gauge NOTE: Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test, fuel pump amperage test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow hack into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. WARNING: The fuel system is under constant fuel pressure even with the engine off. Before disconnecting fuel line at fuel rail, this pressure must be released. Refer to the fuel system pressure release procedure. NOTE: To perform this test you will need to remove the engine cover. 1. Remove the protective cap at the fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port pressure fitting on the fuel rail. 2. Start and warm the engine and note pressure gauge reading. Fuel pressure should be 3.39 kPa +/- 34 kPa (49.2 psi +/- 5 psi) at idle. 3. If engine runs but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, replace fuel pump module assembly. Refer to Fuel Pump Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel filter/fuel pressure regulator. Certain filter/regulators may be serviced separately and some require the replacement of the fuel pump module assembly Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2184 Fuel Pressure: Testing and Inspection Fuel Pump Amperage Test This amperage (current draw) test is to be done in conjunction with the Fuel Pump Pressure Test, Fuel Pump Capacity Test and Fuel Pressure Leak Down Test. Before performing the amperage test, be sure the temperature of the fuel tank is above 50° F (10° C). The DRB Scan Tool along with the DRB Low Current Shunt (LCS) adapter and its test leads will be used to check fuel pump amperage specifications. Low Current Shunt Adapter 1. Obtain LCS adapter. 2. Plug cable from LCS adapter into DRB scan tool at SET 1 receptacle. 3. Plug DRB into vehicle 16-way connector (data link connector). 4. Connect (-) and (+) test cable leads into LCS adapter receptacles. Use 10 amp (10A +) receptacle and common (-) receptacles. 5. Gain access to MAIN MENU on DRB screen. 6. Press DVOM button on DRB. 7. Using left/right arrow keys, highlight CHANNEL 1 function on DRB screen. 8. Press ENTER three times. 9. Using up/down arrow keys, highlight RANGE on DRB screen (screen will default to 2 amp scale). 10. Press ENTER to change 2 amp scale to 10 amp scale. This step must be done to prevent damage to DRB scan tool or LCS adapter (blown fuse). 11. Remove cover from Power Distribution Center (PDC). 12. Remove fuel pump relay from PDC. Refer to label on PDC cover for relay location. WARNING: BEFORE PROCEEDING TO NEXT STEP, NOTE THE FUEL PUMP WILL BE ACTIVATED AND SYSTEM PRESSURE WILL BE PRESENT. THIS WILL OCCUR AFTER CONNECTING TEST LEADS FROM LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES. THE FUEL PUMP WILL OPERATE EVEN WITH IGNITION KEY IN OFF POSITION. BEFORE ATTACHING TEST LEADS, BE SURE ALL FUEL LINES AND FUEL SYSTEM COMPONENTS ARE CONNECTED. CAUTION: To prevent possible damage to the vehicle electrical system and LCS adapter, the test leads must be connected into relay cavities exactly as shown in following steps. Depending upon vehicle model, year or engine configuration, three different types of relays may be used: Type-1, type-2 and type-3. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2185 Starter Relay 13 If equipped with type-1 relay, attach test leads from LCS adapter into PDC relay cavities number 30 and 87. For location of these cavities, refer to numbers stamped to bottom of relay. Type-2 Relay 14. If equipped with type-2 relay, attach test leads from LCS adapter into PDC relay cavities number 30 and 87. For location of these cavities, refer to numbers stamped to bottom of relay. Type-3 Relay 15. If equipped with type-3 relay, attach test leads from LCS adapter into PDC relay cavities number 3 and 5. For location of these cavities, refer to numbers stamped to bottom of relay. 16. When LCS adapter test leads are attached into relay cavities, fuel pump will be activated. Determine fuel pump amperage on DRB screen. Amperage should be below 10.0 amps. If amperage is below 10.0 amps, and specifications for the Fuel Pump Pressure, Fuel Pump Capacity and Fuel Pressure Leak Down tests were met, the fuel pump module is OK. 17. If amperage is more than 10.0 amps, replace fuel pump module assembly The electric fuel pump is not serviced separately. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2186 18. Disconnect test leads from relay cavities immediately after testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2187 Fuel Pressure: Testing and Inspection Fuel Pump Capacity Test NOTE: Before performing this test, verify fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. - Refer to the Fuel Pressure Release Procedure. 2. Disconnect the fuel supply line at fuel rail. - Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. - Insert other end of Adaptor Tool hose into a graduated container. 4. Remove the fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. - Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. - Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions Air/Fuel Mixture: Technical Service Bulletins Fuel System/Engine Controls - Manual Revisions NUMBER: 26-02-99A GROUP: Miscellaneous DATE: February, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revision to the Diagnostic Trouble Codes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2192 45 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2193 46 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2194 47 Revision to the Throttle Position Sensor connector pin outs Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2195 152 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2196 156 Revision to the Fuel System Rich test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2197 316 Revisions to the Throttle Position sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2198 620 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2199 622 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ......................................................... 500 to 900 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2203 Idle Speed: Testing and Inspection The following test procedure has been developed to check throttle body calibrations for correct idle conditions. The procedure should be used to diagnose the throttle body for conditions that may cause idle problems. This procedure should be used only after normal diagnostic procedures have failed to produce results that indicate a throttle body related problem. Be sure to check for proper operation of the idle air control motor before performing this test. Fig. 73 Fixed Orifice Tool A special fixed orifice tool (number 6714) must be used for the following test. 1. Start the engine and bring to operating temperature. Be sure all accessories are off before performing this test. 2. Shut off the engine and remove the air cleaner element housing. Fig. 74 Install Orifice Tool 3. Disconnect the vacuum line at the PCV valve. 4. Install the 0.185 inch orifice tool (number 6714) into the disconnected vacuum line in place of the PCV valve. Fig. 75 Idle Purge Line Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2204 5. Disconnect the idle purge vacuum line from fitting at throttle body This vacuum line is located on the front of throttle body next to the MAP sensor. Cap the fitting at throttle body after vacuum line has been removed. 6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under the instrument panel to the left of the steering column. 7. Start the engine. 8. Using the DRB scan tool, scroll through the menus as follows: select-System, select-Engine, select-Fuel and Ignition, select-Actuator Tests, select Engine rpm and select-Minimum Air Flow. 9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm. The idle rpm should be between 500 and 900 rpm. If the idle speed is outside of these specifications, replace the throttle body. 10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV valve. 13. Install air cleaner element housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair Fig 52 Air Cleaner Components -- Typical REMOVAL 1. From engine compartment, remove plastic air intake tube at front of air cleaner housing. Tube snaps onto air cleaner housing. 2. Remove engine cover. 3. Pull crankcase breather/filter (straight up) from engine valve cover. 4. Remove wing nut and remove air cleaner assembly from throttle body. INSTALLATION 1. Position air cleaner housing to throttle body. 2. If housing-to-throttle body mounting stud is being installed, tighten to 10 N.m (90 in. lbs.) torque. 3. Tighten wingnut to 1.5 N.m (15 in. lbs.) torque. 4. Push crankcase breather/filter into valve cover. 5. Install plastic air intake tube to housing. 6. Install engine cover. AIR CLEANER ELEMENT Housing removal is not necessary for element (filter) replacement. REMOVAL 1. Remove engine cover. 2. Remove wingnut and remove cover from housing. 3. Remove air cleaner element from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Install housing cover to housing. 3. Install wingnut. 4. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair NOTE: Use following procedure if fuel rail is or is not equipped with fuel pressure test port. 1. Remove fuel fill cap. 2. The fuel filler tube contains a spring-loaded flap (door) located below fuel fill cap. The flap is used as a secondary way of sealing fuel tank if fuel fill cap has not been properly tightened. It is part of EVAP monitor system when vehicle is equipped with a Leak Detection Pump (LDP). The vehicle may be equipped with flap installed into fuel filler tube even though vehicle is not equipped with LDP and EVAP monitor system. Place a nonmetallic object into fuel fill tube and press on flap to relieve any tank pressure. 3. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 7. Unplug connector from any injector. 8. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 9. Connect other end of jumper wire to positive side of battery. 10. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 11. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 12. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 13. Disconnect quick-connect fitting at fuel rail. 14. Return fuel pump relay to PDC. 15. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2227 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2228 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2229 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2230 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2231 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2232 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2238 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2239 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2240 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2241 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2242 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2243 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2244 Ignition Cable: Specifications MINIMUM = MAXIMUM 250 Ohms Per Inch = 1000 Ohms Per Inch 3000 Ohms Per Foot = 12,000 Ohms Per Foot Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2245 Ignition Cable: Description and Operation SYSTEM OPERATION Spark plug cables are sometimes referred to as secondary ignition wires. These cables transfer electrical current from the ignition coil(8) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2246 Ignition Cable: Testing and Inspection Heat Shields Check the spark plug cable connections for good contact at the coil(s), distributor cap towers, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, distributor and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean high voltage ignition cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Spark plug cable heat shields are pressed into the cylinder head to surround each spark plug cable boot and spark plug . These shields protect the spark plug boots from damage (due to intense engine heat generated by the exhaust manifolds) and should not be removed. After the spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat shield. Testing When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment manufacturer. If an oscilloscope is not available, spark plug cables may be tested as follows: CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. With the engine running, remove spark plug cable from spark plug (one at a time) and hold next to a good engine ground. If the cable and spark plug are in good condition, the engine rpm should drop and the engine will run poorly If engine rpm does not drop, the cable and/or spark plug may not be operating properly and should be replaced. Also check engine cylinder compression. With the engine not running, connect one end of a test probe to a good ground. Start the engine and run the other end of the test probe along the entire length of all spark plug cables. If cables are cracked or punctured, there will be a noticeable spark jump from the damaged area to the test probe. The cable running from the ignition coil to the distributor cap can be checked in the same manner. Cracked, damaged or faulty cables should be replaced with resistance type cable. This can be identified by the words ELECTRONIC SUPPRESSION printed on the cable jacket. Use an ohmmeter to test for open circuits, excessive resistance or loose terminals. If equipped, remove the distributor cap from the distributor. Do not remove cables from cap. Remove cable from spark plug. Connect ohmmeter to spark plug terminal end of cable and to corresponding electrode in distributor cap. Resistance should be 250 to 1000 Ohms per inch of cable. If not, remove cable from distributor cap tower and connect ohmmeter to the terminal ends of cable. If resistance is not within specifications as found in the SPARK PLUG CABLE RESISTANCE chart, replace the cable. Test all spark plug cables in this manner. Spark Plug Cable Resistance MINIMUM = MAXIMUM 250 Ohms Per Inch = 1000 Ohms Per Inch 3000 Ohms Per Foot = 12,000 Ohms Per Foot To test ignition coil-to-distributor cap cab]e, do not remove the cable from the cap. Connect ohmmeter to rotor button (center contact) of distributor cap and terminal at ignition coil end of cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, remove the cable from the distributor cap. Connect the ohmmeter to the terminal ends of the cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, replace the cable. Inspect the ignition coil tower for cracks, burns or corrosion. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2247 Ignition Cable: Service and Repair REMOVAL AND INSTALLATION Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Engine Firing Order Install cables into the proper engine cylinder firing order. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Cap Inspection-External-Typical Cap Inspection-Internal-Typical Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. The machined surface of a terminal end (faces toward rotor) will indicate some evidence of erosion from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Rotor Inspection-Typical Visually inspect the rotor for cracks, evidence of corrosion or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... ..................................................... 0.89 mm (0.035 in) Torque ............................................................ ............................................................................................................................................... 41 Nm (30 ft lb) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2258 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ..................................................................... RC12YC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2259 Spark Plug: Description and Operation SYSTEM OPERATION All engines use resistor type spark plugs. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Spark plugs that have low milage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2260 Spark Plug: Testing and Inspection Normal Operating Spark Plug Cable Resistance The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Cold Fouling/Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operating times (short trips). Wet Fouling Or Gas Fouling A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Oil Or Ash Encrusted Oil Or Ash Encrusted If one or more spark plugs are oil or oil ash encrusted, evaluate engine condition for the cause of oil entry into that particular combustion chamber. Electrode Gap Bridging Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2261 Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Scavenger Deposits Scavenger Deposit Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy, but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Chipped Electrode Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Preignition Damage Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2262 Preignition Damage Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Spark Plug Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2263 Spark Plug: Service and Repair Heat Shields Spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. PLUG REMOVAL 1. Remove engine cover. 2. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result, 3. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber. 4. Remove the spark plug using a quality socket with a rubber or foam insert. 5. Inspect the spark plug condition. Plug Cleaning The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator arid will cause plug misfire. Plug Gap Adjustment Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. Spark Plug Gap V-8 Engines: 1.01 mm (.040 in). PLUG INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. when replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 N.m (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi) from cylinder to cylinder. If cylinder(s) have abnormally low compression pressures, repeat procedure. - If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a problem in the cylinder. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should NOT be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2267 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. Minimum cylinder compression pressure is 689 kPa (100 psi). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications IAT Sensor IAT Sensor Torque 28 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2275 Intake Air Temperature Sensor: Locations Intake Manifold Air TEMPT Sensor, Electrical CONN Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2276 Intake Air TEMPT Sensor CONN Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2277 Intake Air Temperature Sensor: Testing and Inspection Fig. 69 Intake Manifold Air Temperature Sensor 1. Disconnect the wire harness connector from the intake manifold air temperature sensor. Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. Refer to the Coolant Temperature sensor/Intake Air Temperature sensor resistance chart. Replace the sensor if it is not within the range of resistance specified in the chart. 3. Test the resistance of the wire harness. Do this between the Powertrain Control Module (PCM) wire harness connector A-15 and the sensor connector terminal. Also check between PCM connector A-4 to the sensor connector terminal. Repair the wire harness as necessary if the resistance is greater than 1 ohm. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2278 Intake Air Temperature Sensor: Service and Repair Fig 57 Air Temperature Sensor REMOVAL 1. Disconnect electrical connector at sensor. 2. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 N.m (20 ft. lbs.) torque. 2. Install electrical connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Tray, Battery Tempt Sensor, Engine Wiring Harness, Sensor Harness Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2282 Battery Temperature Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2283 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2284 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry. refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pig-tail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 2287 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. Refer to Starting and Charging/Battery 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Refer to Starting and Charging/Battery Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Module Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 2292 Central Timer Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2295 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2296 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2297 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2298 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2299 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2300 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2301 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2302 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2303 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2304 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2305 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2306 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2307 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2308 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2309 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2310 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2311 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2312 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2313 Body Control Module: Connector Views CTM Connector CTM Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2314 Body Control Module: Electrical Diagrams Central Timer Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2315 Vehicle Communications Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Central Timer Module Description Body Control Module: Description and Operation Central Timer Module Description The AB HIGH LINE utilize a Central Timer Module (CTM). The Base AB RAM VAN will not be addressed in this manual. For concerns about the Base AB VAN, please refer to the appropriate service and repair article. The CTM performs most of the typical functions a Body Control Module would perform. The CTM provides the following features: - Remote Keyless Entry (RKE) - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks WIRKE - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Vehicle Theft Security System (VTSS) The module is located on the left center instrument panel support. It contains a white 18-way and a green 14-way connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Central Timer Module Description > Page 2318 Body Control Module: Description and Operation System Description and Functional Operation The body system on the 1998 AB HIGH LINE consists of three modules that communicate over the CCD bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-Lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication. The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are performed through the Serial Communication Interface of SCI, the same as previous years. All of the information about the functioning of all the system is organized, controlled, and communicated by the CCD bus, which is described in Section 3 (CCD Bus) of this general information section. Through the CCD bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all the information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics Identification of Systems The vehicle Systems that are part of the "body" system are: - Airbag System (ACM) - Central Timer Module (CTM) - Instrument Cluster (MIC) - Vehicle Communication Diagnostic Strategies Diagnosis of the central timer module (CTM) is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem verification of proper operation Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2324 Camshaft Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2325 Camshaft Position Sensor: Description and Operation SYSTEM OPERATION The camshaft position sensor is located in the distributor on all engines. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2326 Camshaft Position Sensor: Testing and Inspection Camshaft Position Sensor - Typical The camshaft position sensor is located in the distributor on all engines. To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostics Procedures service. To test the sensor only, refer to the following: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Remove engine cover. 2. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. For wire identification. 3. Connect the negative (-) voltmeter lead into the ground wire. For wire identification. 4. Set the voltmeter to the 15 Volt DC scale. 5. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 6. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 7. If voltage is not present, check the voltmeter leads for a good connection. 8. If voltage is still not present, check for voltage at the supply wire. For wire identification. 9. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 10. If voltage is still not present, perform vehicle test using the DRB scan tool. 11. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM. If continuity is not present, repair the harness as necessary c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 12. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2327 Camshaft Position Sensor: Service and Repair The camshaft position sensor is located in the distributor. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove engine cover. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. Crankshaft Position Sensor 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls ECT Sensor Test revisions NUMBER: 26-11-97F GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L/4.0L/5.2L/5.9L SFI Engine Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revisions to the ECT sensor voltage too high test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions > Page 2332 165 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2333 Coolant Temperature Sensor/Switch (For Computer): Specifications Torque 11 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2334 Coolant Temperature Sensor/Switch (For Computer): Locations Generator, A/C Compressor, Elec.CONN, Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2335 Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2336 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Fig 1 Powertrain Control Module To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: 1. Vehicles equipped with air conditioning: a. Disconnect the negative battery cable at battery. b. Remove Jeep/Truck Engine Controller (JTEC) mounting bolts and remove JTEC. Do not disconnect three 32-way connectors from JTEC. Fig. 66 Engine Coolant Temperature Sensor 2. Disconnect wire harness connector from coolant temperature sensor. 3. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2337 Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 4. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 5. Test continuity of the wire harness between the JTEC wire harness connector and the coolant sensor connector terminals. - Refer to Diagrams/connector Views. - Repair the wire harness if an open circuit is indicated. 6. After tests are completed, connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2338 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING COOLANT TEMPERATURE SENSOR. Engine Coolant Temperature Sensor Location The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. 1. Disconnect negative battery cable at battery. 2. Place a small mirror above sensor connector. 3. Disconnect electrical connector from sensor. When removing connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place hook part of tool under connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Partially drain cooling system. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor into intake manifold. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. 5. Connect negative battery cable at battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Mounting Bolts 8 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2342 Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2343 Crankshaft Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2344 Crankshaft Position Sensor: Description and Operation SYSTEM OPERATION Sensor Operation Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. On this engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2345 Crankshaft Position Sensor: Testing and Inspection To perform a complete test of this sensor and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2346 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor - Typical The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. 1. Remove engine cover. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 N.m (70 in.lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Data Link Connector Data Link Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2350 Data Link Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall Reprogram PCM Technical Service Bulletin # 831 Date: 990601 Recall - Reprogram PCM June 1999 California Emissions Recall No. 831 Reprogram Powertrain Control Module Models 1998 (DN) Dodge Durango (with a 5.9L engine and automatic transmission) (AB) Dodge Ram Van/Wagon (with a 5.9L engine and automatic transmission) (ZJ) Jeep(R) Grand Cherokee (with a 5. 9L engine and automatic transmission) (AN) Dodge Dakota (with 5.2L engine and manual transmission or 5.9L engine and automatic transmission) (BR/BE)Dodge Ram Pickup (with a 5.2L engine and manual transmission, 5.9L engine and automatic transmission or 8.0L engine) NOTE: This recall applies only to certain vehicles equipped with a California emission control system (sales code NAE) built through April 30, 1998 (MDH 0430XX). Subject The On-Board Diagnostic (OBD) system on about 18,000 of the above vehicles may not detect evaporative emissions purge system malfunctions as required by California Emission Regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update labels and Authorized Modifications labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance PCM Update Previously Performed 08831181 0.2 hours Reprogram Powertrain Control Module 08831182 0.5 hours Add the cost of the labels plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall Reprogram PCM > Page 2359 Not Applicable Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD831". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure The DRB III(R) with either MDS1 or MDS2 is required to perform this repair. ^ If using the MDS1 and DRB III, the MDS must be operating at release 21 or higher and TIL CD release 1184 or higher must be installed. ^ If using the MDS2 and DRB III, the system must be operating at CIS CD2034 or higher. Using the MDS1 1. Connect the MDS1 (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 - CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU screen. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III UPDATE on the DRB III MAIN MENU. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER REPROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS1 AND DRB III on the MDS1, then press NEXT MENU. 7. FOLLOW THE STEPS PRESENTED ON THE MDS1 and DRB III that will allow the DRB III to obtain the current part number of the PCM. 8. The MDS1 will display the part number of the PCM on the vehicle and the appropriate replacement part number(s). Press NEXT MENU to begin programming. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall Reprogram PCM > Page 2360 9. The MDS and DRB III will prompt the operator for any action needed during the remainder of the programming process. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Step C. Using the MDS2 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. B. Install Authorized Software Update Label Fig. 1 Type or print (with a ballpoint pen) the necessary information on the "Authorized Software Update" label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Label Fig. 2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall Reprogram PCM > Page 2361 Type or print (with a ballpoint pen) the necessary information shown in Figure 2 onto the Authorized Modifications Label. Then attach the label near the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Owner Letter EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE Dear DaimlerChrysler Vehicle Owner: DaimlerChrysler has determined that some 1998 Dodge Dakota, Durango, Ram Van/Wagon, Ram Truck, and Jeep(R) Grand Cherokee vehicles, equipped with a V-8 or V-10 engine, may be in violation of California Emissions Regulations. The problem is... The On-Board Diagnostic (OBD) system on your vehicle (identified on the enclosed form) may not detect evaporative emissions purge system malfunctions as required by California Emissions Regulations. As a result, the OBD system on your vehicle may not illuminate the "Check Engine" light if the evaporative emissions purge system malfunctions. This could cause your vehicle to emit hydrocarbon levels above the limits that were established to protect the public health from the dangers of air pollution. Hydrocarbons (unburned fuel) combined with oxides of nitrogen, in the presence of sunlight, can cause the formation of ozone. These pollutants are the primary components of smog. What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will reprogram your vehicle's powertrain control module. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer right away to schedule a service appointment. ^ Bring the enclosed Owner Notification form with you to your dealer. It identifies the required service to the dealer. If you live in California and don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. How the state knows that the recall has been performed... State of California regulations require DaimlerChrysler to provide the Department of Motor Vehicles with a record of all vehicles that have not had the recall service performed. If you live in the state of California and your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. In order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. We are sorry for any inconvenience but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you for your attention to this important matter. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates Powertrain Control Module: All Technical Service Bulletins Engine Controls/Charging System Manual Updates NUMBER: 26-08-99F GROUP: Miscellaneous DATE: August, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998-2.5L, 3.9L, 5.2L, 5.9L, 8.0 SFI/Mechanically Injected Diesel Diagnostic Manual Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the Charging System Low Test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 2367 71 Revision to the 5.2/5.9L PCM Wiring Schematic Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 2368 744 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 > Recall - Reprogram PCM Technical Service Bulletin # 831 Date: 990601 Recall - Reprogram PCM June 1999 California Emissions Recall No. 831 Reprogram Powertrain Control Module Models 1998 (DN) Dodge Durango (with a 5.9L engine and automatic transmission) (AB) Dodge Ram Van/Wagon (with a 5.9L engine and automatic transmission) (ZJ) Jeep(R) Grand Cherokee (with a 5. 9L engine and automatic transmission) (AN) Dodge Dakota (with 5.2L engine and manual transmission or 5.9L engine and automatic transmission) (BR/BE)Dodge Ram Pickup (with a 5.2L engine and manual transmission, 5.9L engine and automatic transmission or 8.0L engine) NOTE: This recall applies only to certain vehicles equipped with a California emission control system (sales code NAE) built through April 30, 1998 (MDH 0430XX). Subject The On-Board Diagnostic (OBD) system on about 18,000 of the above vehicles may not detect evaporative emissions purge system malfunctions as required by California Emission Regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update labels and Authorized Modifications labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance PCM Update Previously Performed 08831181 0.2 hours Reprogram Powertrain Control Module 08831182 0.5 hours Add the cost of the labels plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 2373 Not Applicable Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD831". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure The DRB III(R) with either MDS1 or MDS2 is required to perform this repair. ^ If using the MDS1 and DRB III, the MDS must be operating at release 21 or higher and TIL CD release 1184 or higher must be installed. ^ If using the MDS2 and DRB III, the system must be operating at CIS CD2034 or higher. Using the MDS1 1. Connect the MDS1 (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 - CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU screen. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III UPDATE on the DRB III MAIN MENU. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER REPROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS1 AND DRB III on the MDS1, then press NEXT MENU. 7. FOLLOW THE STEPS PRESENTED ON THE MDS1 and DRB III that will allow the DRB III to obtain the current part number of the PCM. 8. The MDS1 will display the part number of the PCM on the vehicle and the appropriate replacement part number(s). Press NEXT MENU to begin programming. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 2374 9. The MDS and DRB III will prompt the operator for any action needed during the remainder of the programming process. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Step C. Using the MDS2 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. B. Install Authorized Software Update Label Fig. 1 Type or print (with a ballpoint pen) the necessary information on the "Authorized Software Update" label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Label Fig. 2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 2375 Type or print (with a ballpoint pen) the necessary information shown in Figure 2 onto the Authorized Modifications Label. Then attach the label near the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Owner Letter EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE Dear DaimlerChrysler Vehicle Owner: DaimlerChrysler has determined that some 1998 Dodge Dakota, Durango, Ram Van/Wagon, Ram Truck, and Jeep(R) Grand Cherokee vehicles, equipped with a V-8 or V-10 engine, may be in violation of California Emissions Regulations. The problem is... The On-Board Diagnostic (OBD) system on your vehicle (identified on the enclosed form) may not detect evaporative emissions purge system malfunctions as required by California Emissions Regulations. As a result, the OBD system on your vehicle may not illuminate the "Check Engine" light if the evaporative emissions purge system malfunctions. This could cause your vehicle to emit hydrocarbon levels above the limits that were established to protect the public health from the dangers of air pollution. Hydrocarbons (unburned fuel) combined with oxides of nitrogen, in the presence of sunlight, can cause the formation of ozone. These pollutants are the primary components of smog. What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will reprogram your vehicle's powertrain control module. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer right away to schedule a service appointment. ^ Bring the enclosed Owner Notification form with you to your dealer. It identifies the required service to the dealer. If you live in California and don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. How the state knows that the recall has been performed... State of California regulations require DaimlerChrysler to provide the Department of Motor Vehicles with a record of all vehicles that have not had the recall service performed. If you live in the state of California and your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. In order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. We are sorry for any inconvenience but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you for your attention to this important matter. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution Powertrain Control Module: All Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions Powertrain Control Module: All Technical Service Bulletins Engine Controls/Fuel System - Service Manual Revisions NUMBER: 26-12-97H GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L, 3.9L, 5.2L, 8.0L Powertrain Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the "No Cam Signal at PCM" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 2384 29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 2385 56 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 2386 58 Revision to the "Fuel Level Sending Unit" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 2387 412 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates Powertrain Control Module: All Technical Service Bulletins Engine Controls/Charging System Manual Updates NUMBER: 26-08-99F GROUP: Miscellaneous DATE: August, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998-2.5L, 3.9L, 5.2L, 5.9L, 8.0 SFI/Mechanically Injected Diesel Diagnostic Manual Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the Charging System Low Test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 2393 71 Revision to the 5.2/5.9L PCM Wiring Schematic Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 2394 744 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution Powertrain Control Module: All Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions Powertrain Control Module: All Technical Service Bulletins Engine Controls/Fuel System - Service Manual Revisions NUMBER: 26-12-97H GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L, 3.9L, 5.2L, 8.0L Powertrain Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the "No Cam Signal at PCM" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 2403 29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 2404 56 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 2405 58 Revision to the "Fuel Level Sending Unit" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 2406 412 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2407 Powertrain Control Module: Specifications Mounting Screws 1 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2408 Powertrain Control Module: Locations Fig 1 Powertrain Control Module The Powertrain Control Module (PCM) is located under the hood; mounted to the cowling, near the wiper motor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2411 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2412 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2413 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2414 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2415 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2416 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2417 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2418 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2419 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2420 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2421 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2422 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2423 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2424 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2425 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2426 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2427 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2428 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2429 Powertrain Control Module: Connector Views Powertrain Control Module Connectors Powertrain Control Module C1 - Black Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2430 C1 - Black C2 - White C2 - White C3 - Grey Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2431 C3 - Grey Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2432 Powertrain Control Module: Description and Operation SYSTEM OPERATION Powertrain Control Module (PCM) The Powertrain Control Module (PCM) is located in the engine compartment. The ignition system is controlled by the PCM. NOTE: Base ignition timing by rotation of distributor is not adjustable. The PCM opens and closes the ignition coil ground circuit to operate the ignition coil. This is done to adjust ignition timing, both initial (base) and advance, and for changing engine operating conditions. The amount of electronic spark advance provided by the PCM is determined by five input factors: engine coolant temperature, engine rpm, intake manifold temperature, manifold absolute pressure and throttle position. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Module Replacement Powertrain Control Module: Service and Repair Module Replacement Fig 1 Powertrain Control Module REMOVAL 1. Disconnect the negative battery cable at battery. 2. Carefully unplug the three 32-way connectors from PCM. 3. Remove three Powertrain Control Module (PCM) mounting bolts and remove PCM from vehicle. INSTALLATION 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 4 N.m (35 in. lbs.). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary 4. Install three 32-way connectors. 5. Install battery cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Module Replacement > Page 2435 Powertrain Control Module: Service and Repair A Note About PCM Replacement Important Note: If the Powertrain Control Module has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS, Airbag and SKIM modules. In addition, if the vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. For ABS and Airbag Systems: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Airbag modules. For SKIM Theft Alarm: 1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. 3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM (this is required to allow the vehicle to start with the new PCM). 4. If three attempts are made to enter secured access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lock out mode, leave the ignition key in the Run/Start position for one hour. Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications IAC Motor IAC Motor Mounting Bolts 7 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2439 Idle Speed/Throttle Actuator - Electronic: Locations Map Sensor,idle Air Control Motor,TP Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2440 Idle Air Control Motor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2441 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection To perform a complete test of the idle air control motor and circuits see Computers and Control Systems /System Diagnosis/Procedures/Diagnostic Charts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2442 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL 1. Remove air cleaner assembly. 2. Disconnect electrical connector from Idle Air Control (IAC) motor. Fig. 84 Mounting Bolts (Screws) - IAC 3. Remove two mounting bolts (screws). 4. Remove IAC motor from throttle body INSTALLATION 1. Install IAC motor to throttle body 2. Install and tighten two mounting bolts (screws) to 7 N.m (60 in. lbs.) torque. 3. Install electrical connector. 4. Install air cleaner assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Auto Shutdown Relay Connector, Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2446 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2447 Auto Shutdown Relay Connector, Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2448 Automatic Shut Down (ASD) Relay: Description and Operation SYSTEM OPERATION As one of its functions, the (ASD) relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2449 Automatic Shut Down (ASD) Relay: Testing and Inspection Fig. 24 Asd And Fuel Pump Relay Terminals The relay terminal numbers can be found on the bottom of the relay: - Terminal number 30 is connected to battery voltage and can be switched or B+ (hot) at all times. - The center terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the component being operated. - Terminal number 86 is connected to a switched (+) power source. - Terminal number 85 is grounded by the Powertrain Control Module (PCM). TESTING 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. - Resistance value (ohms) should be 75 +/- 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. - Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. - Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). - Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. - Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. - Continuity should now be present between terminals number 87 and 30. - Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 volt power source. If continuity or resistance tests did not pass, replace relay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2450 Automatic Shut Down (ASD) Relay: Service and Repair Fig 2 Power Distribution Center The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC coven 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. - Also check the heights of relay terminal pins at PDC. - Pin height should be same for all pins. - Repair as necessary before installing relay. 2. Push the relay into the connector. 3. Install the relay cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Data Link Connector As a functional test, the MIL (check engine) illuminates at key-on before engine cranking. Whenever the Powertrain Control Module (PCM) sets a Diagnostic Trouble Code (DTC) that affects vehicle emissions, it illuminates the MIL. If a problem is detected, the PCM sends a message to the instrument cluster to illuminate the lamp. The PCM illuminates the MIL only for DTC's that affect vehicle emissions. There are some monitors that may take two consecutive trips, with a detected fault, before the MIL is illuminated. The MIL stays on continuously when the PCM has entered a Limp-In mode or identified a failed emission component. Also, the MIL either flashes or illuminates continuously when the PCM detects active engine misfire. Additionally, the PCM may reset (turn off) the MIL when one of the following occur: ^ PCM does not detect the malfunction for 3 consecutive trips (except misfire and Fuel system Monitors). ^ PCM does not detect a malfunction while performing three successive engine misfire or fuel system tests. The PCM performs these tests while the engine is operating within ± 375 RPM of and within 10 % of the load of the operating condition at which the malfunction was first detected. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2454 Malfunction Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative malfunction indicator (Check Engine) lamp condition. If the lamp comes on and stays on with the engine running, refer to Powertrain Management/Computers and Control Systems/Testing and Inspection. See: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the malfunction indicator lamp falls to light during the bulb test (about two seconds after the ignition switch is turned to the On position), replace the malfunction indicator lamp bulb with a known good unit. If the indicator lamp still fails to operate, diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For further diagnosis of the malfunction indicator lamp and the instrument cluster circuitry, refer to Instrument Panel/Testing and Inspection. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Mounting Screws 3 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2458 Manifold Pressure/Vacuum Sensor: Locations Fig. 15 MAP And Throttle Position Sensor Location - Typical Map Sensor, Idle Air Control Motor, Throttle Position Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2459 Map Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2460 Manifold Pressure/Vacuum Sensor: Testing and Inspection Fig 57 Manifold Absolute Pressure Sensor 1. Inspect the rubber L-shaped fitting from the Manifold Absolute Pressure (MAP) sensor to the throttle body. Repair as necessary. CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. Fig 58 Rubber L-Shaped Fitting -- MAP Sensor-to-Throttle Body Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2461 Fig 33 MAP Sensor Connector Terminals -- Typical 2. Test the MAP sensor output voltage at the MAP sensor connector between terminals A and B. With the ignition switch ON and the engine OFF, output voltage should be 4-to-5 volts. The voltage should drop to 1.5-to-2.1 volts with a hot, neutral idle speed condition. 3. Test Powertrain Control Module (PCM) cavity A-27 for the same voltage described above to verify the wire harness condition. Repair as necessary. 4. Test MAP sensor supply voltage at sensor connector between terminals A and C with the ignition ON. The voltage should be approximately 5 volts (+/- 0.5V). Five volts (+/- 0.5V) should also be at cavity A-17 of the PCM wire harness connector. Repair or replace the wire harness as necessary 5. Test the MAP sensor ground circuit at sensor connector terminal-A and PCM connector A-4. Repair the wire harness if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2462 Manifold Pressure/Vacuum Sensor: Service and Repair Fig 86 MAP Sensor Location The Manifold Absolute Pressure (MAP) sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. NOTE: The throttle body must be removed from the intake manifold for MAP sensor removal. REMOVAL 1. Remove air cleaner assembly. 2. Remove throttle body. 3. Remove two MAP sensor mounting bolts (screws). 4. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body 5. Remove rubber L-shaped fitting from MAP sensor. Fig 87 MAP Sensor L-Shaped Rubber Fitting INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 N.m (25 in. lbs.) torque. 4. Install throttle body. 5. Install air cleaner. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions Oil Pressure Sensor: Technical Service Bulletins Engine Controls/Fuel System - Manual Revisions NUMBER: 26-01-99C GROUP: Miscellaneous DATE: January, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Powertrain 2.5L. 3.9L, 5.2L, 5.9L, 8.0 SFI, Mechanical Injected Diesel Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revision to the Table of Contents Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2467 vi Revision to the Trouble Code Test menu Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2468 538 Revision to the Oil Pressure Sensor test 589, 589A through 589F Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2469 589 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2470 589A Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2471 589B Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2472 589C Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2473 589D Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2474 589E Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2475 589F Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Torque 30 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2481 JTEC O2 Sensor Location Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2482 Oxygen Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2483 Oxygen Sensor: Application and ID Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2484 Oxygen Sensor: Testing and Inspection Fig 6 Heated Oxygen Sensors The upstream O2S sensor is located on the inlet end of the catalytic converter. The downstream O2S sensor is located on the outlet end of the catalytic converter. Each O2S heating element can be tested with an ohmmeter as follows: Disconnect the O2S sensor connector. Connect the ohmmeter test leads across the white wire terminals of the sensor connector. Resistance should be between 4 and 7 ohms. Replace the sensor if the ohmmeter displays an infinity (open) reading. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2485 Oxygen Sensor: Service and Repair Fig 6 Heated Oxygen Sensors NOTE: The O2S sensors are located at the inlet and outlet ends of the catalytic converter. WARNING: The exhaust manifold, exhaust pipes and catalytic converter become very hot during engine operation. Allow engine to cool before removing oxygen sensor. REMOVAL 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. NOTE: Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. INSTALLATION 1. Install the O2S sensor. Tighten to 30 N.m (22 ft. lbs.) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Module Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 2491 Central Timer Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2494 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2495 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2496 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2497 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2498 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2499 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2500 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2501 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2502 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2503 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2504 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2505 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2506 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2507 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2508 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2509 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2510 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2511 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2512 Body Control Module: Connector Views CTM Connector CTM Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2513 Body Control Module: Electrical Diagrams Central Timer Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2514 Vehicle Communications Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Central Timer Module Description Body Control Module: Description and Operation Central Timer Module Description The AB HIGH LINE utilize a Central Timer Module (CTM). The Base AB RAM VAN will not be addressed in this manual. For concerns about the Base AB VAN, please refer to the appropriate service and repair article. The CTM performs most of the typical functions a Body Control Module would perform. The CTM provides the following features: - Remote Keyless Entry (RKE) - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks WIRKE - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Vehicle Theft Security System (VTSS) The module is located on the left center instrument panel support. It contains a white 18-way and a green 14-way connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Central Timer Module Description > Page 2517 Body Control Module: Description and Operation System Description and Functional Operation The body system on the 1998 AB HIGH LINE consists of three modules that communicate over the CCD bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-Lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication. The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are performed through the Serial Communication Interface of SCI, the same as previous years. All of the information about the functioning of all the system is organized, controlled, and communicated by the CCD bus, which is described in Section 3 (CCD Bus) of this general information section. Through the CCD bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all the information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics Identification of Systems The vehicle Systems that are part of the "body" system are: - Airbag System (ACM) - Central Timer Module (CTM) - Instrument Cluster (MIC) - Vehicle Communication Diagnostic Strategies Diagnosis of the central timer module (CTM) is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem verification of proper operation Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM Technical Service Bulletin # 831 Date: 990601 Recall - Reprogram PCM June 1999 California Emissions Recall No. 831 Reprogram Powertrain Control Module Models 1998 (DN) Dodge Durango (with a 5.9L engine and automatic transmission) (AB) Dodge Ram Van/Wagon (with a 5.9L engine and automatic transmission) (ZJ) Jeep(R) Grand Cherokee (with a 5. 9L engine and automatic transmission) (AN) Dodge Dakota (with 5.2L engine and manual transmission or 5.9L engine and automatic transmission) (BR/BE)Dodge Ram Pickup (with a 5.2L engine and manual transmission, 5.9L engine and automatic transmission or 8.0L engine) NOTE: This recall applies only to certain vehicles equipped with a California emission control system (sales code NAE) built through April 30, 1998 (MDH 0430XX). Subject The On-Board Diagnostic (OBD) system on about 18,000 of the above vehicles may not detect evaporative emissions purge system malfunctions as required by California Emission Regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update labels and Authorized Modifications labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance PCM Update Previously Performed 08831181 0.2 hours Reprogram Powertrain Control Module 08831182 0.5 hours Add the cost of the labels plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 2528 Not Applicable Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD831". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure The DRB III(R) with either MDS1 or MDS2 is required to perform this repair. ^ If using the MDS1 and DRB III, the MDS must be operating at release 21 or higher and TIL CD release 1184 or higher must be installed. ^ If using the MDS2 and DRB III, the system must be operating at CIS CD2034 or higher. Using the MDS1 1. Connect the MDS1 (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 - CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU screen. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III UPDATE on the DRB III MAIN MENU. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER REPROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS1 AND DRB III on the MDS1, then press NEXT MENU. 7. FOLLOW THE STEPS PRESENTED ON THE MDS1 and DRB III that will allow the DRB III to obtain the current part number of the PCM. 8. The MDS1 will display the part number of the PCM on the vehicle and the appropriate replacement part number(s). Press NEXT MENU to begin programming. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 2529 9. The MDS and DRB III will prompt the operator for any action needed during the remainder of the programming process. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Step C. Using the MDS2 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. B. Install Authorized Software Update Label Fig. 1 Type or print (with a ballpoint pen) the necessary information on the "Authorized Software Update" label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Label Fig. 2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 2530 Type or print (with a ballpoint pen) the necessary information shown in Figure 2 onto the Authorized Modifications Label. Then attach the label near the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Owner Letter EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE Dear DaimlerChrysler Vehicle Owner: DaimlerChrysler has determined that some 1998 Dodge Dakota, Durango, Ram Van/Wagon, Ram Truck, and Jeep(R) Grand Cherokee vehicles, equipped with a V-8 or V-10 engine, may be in violation of California Emissions Regulations. The problem is... The On-Board Diagnostic (OBD) system on your vehicle (identified on the enclosed form) may not detect evaporative emissions purge system malfunctions as required by California Emissions Regulations. As a result, the OBD system on your vehicle may not illuminate the "Check Engine" light if the evaporative emissions purge system malfunctions. This could cause your vehicle to emit hydrocarbon levels above the limits that were established to protect the public health from the dangers of air pollution. Hydrocarbons (unburned fuel) combined with oxides of nitrogen, in the presence of sunlight, can cause the formation of ozone. These pollutants are the primary components of smog. What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will reprogram your vehicle's powertrain control module. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer right away to schedule a service appointment. ^ Bring the enclosed Owner Notification form with you to your dealer. It identifies the required service to the dealer. If you live in California and don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. How the state knows that the recall has been performed... State of California regulations require DaimlerChrysler to provide the Department of Motor Vehicles with a record of all vehicles that have not had the recall service performed. If you live in the state of California and your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. In order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. We are sorry for any inconvenience but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you for your attention to this important matter. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates Powertrain Control Module: All Technical Service Bulletins Engine Controls/Charging System Manual Updates NUMBER: 26-08-99F GROUP: Miscellaneous DATE: August, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998-2.5L, 3.9L, 5.2L, 5.9L, 8.0 SFI/Mechanically Injected Diesel Diagnostic Manual Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the Charging System Low Test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 2536 71 Revision to the 5.2/5.9L PCM Wiring Schematic Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 2537 744 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 > Recall Reprogram PCM Technical Service Bulletin # 831 Date: 990601 Recall - Reprogram PCM June 1999 California Emissions Recall No. 831 Reprogram Powertrain Control Module Models 1998 (DN) Dodge Durango (with a 5.9L engine and automatic transmission) (AB) Dodge Ram Van/Wagon (with a 5.9L engine and automatic transmission) (ZJ) Jeep(R) Grand Cherokee (with a 5. 9L engine and automatic transmission) (AN) Dodge Dakota (with 5.2L engine and manual transmission or 5.9L engine and automatic transmission) (BR/BE)Dodge Ram Pickup (with a 5.2L engine and manual transmission, 5.9L engine and automatic transmission or 8.0L engine) NOTE: This recall applies only to certain vehicles equipped with a California emission control system (sales code NAE) built through April 30, 1998 (MDH 0430XX). Subject The On-Board Diagnostic (OBD) system on about 18,000 of the above vehicles may not detect evaporative emissions purge system malfunctions as required by California Emission Regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update labels and Authorized Modifications labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance PCM Update Previously Performed 08831181 0.2 hours Reprogram Powertrain Control Module 08831182 0.5 hours Add the cost of the labels plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 > Recall Reprogram PCM > Page 2542 Not Applicable Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD831". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure The DRB III(R) with either MDS1 or MDS2 is required to perform this repair. ^ If using the MDS1 and DRB III, the MDS must be operating at release 21 or higher and TIL CD release 1184 or higher must be installed. ^ If using the MDS2 and DRB III, the system must be operating at CIS CD2034 or higher. Using the MDS1 1. Connect the MDS1 (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 - CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU screen. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III UPDATE on the DRB III MAIN MENU. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER REPROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS1 AND DRB III on the MDS1, then press NEXT MENU. 7. FOLLOW THE STEPS PRESENTED ON THE MDS1 and DRB III that will allow the DRB III to obtain the current part number of the PCM. 8. The MDS1 will display the part number of the PCM on the vehicle and the appropriate replacement part number(s). Press NEXT MENU to begin programming. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 > Recall Reprogram PCM > Page 2543 9. The MDS and DRB III will prompt the operator for any action needed during the remainder of the programming process. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Step C. Using the MDS2 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. B. Install Authorized Software Update Label Fig. 1 Type or print (with a ballpoint pen) the necessary information on the "Authorized Software Update" label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Label Fig. 2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 > Recall Reprogram PCM > Page 2544 Type or print (with a ballpoint pen) the necessary information shown in Figure 2 onto the Authorized Modifications Label. Then attach the label near the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Owner Letter EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE Dear DaimlerChrysler Vehicle Owner: DaimlerChrysler has determined that some 1998 Dodge Dakota, Durango, Ram Van/Wagon, Ram Truck, and Jeep(R) Grand Cherokee vehicles, equipped with a V-8 or V-10 engine, may be in violation of California Emissions Regulations. The problem is... The On-Board Diagnostic (OBD) system on your vehicle (identified on the enclosed form) may not detect evaporative emissions purge system malfunctions as required by California Emissions Regulations. As a result, the OBD system on your vehicle may not illuminate the "Check Engine" light if the evaporative emissions purge system malfunctions. This could cause your vehicle to emit hydrocarbon levels above the limits that were established to protect the public health from the dangers of air pollution. Hydrocarbons (unburned fuel) combined with oxides of nitrogen, in the presence of sunlight, can cause the formation of ozone. These pollutants are the primary components of smog. What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will reprogram your vehicle's powertrain control module. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer right away to schedule a service appointment. ^ Bring the enclosed Owner Notification form with you to your dealer. It identifies the required service to the dealer. If you live in California and don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. How the state knows that the recall has been performed... State of California regulations require DaimlerChrysler to provide the Department of Motor Vehicles with a record of all vehicles that have not had the recall service performed. If you live in the state of California and your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. In order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. We are sorry for any inconvenience but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you for your attention to this important matter. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution Powertrain Control Module: All Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions Powertrain Control Module: All Technical Service Bulletins Engine Controls/Fuel System - Service Manual Revisions NUMBER: 26-12-97H GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L, 3.9L, 5.2L, 8.0L Powertrain Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the "No Cam Signal at PCM" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 2553 29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 2554 56 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 2555 58 Revision to the "Fuel Level Sending Unit" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 2556 412 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates Powertrain Control Module: All Technical Service Bulletins Engine Controls/Charging System Manual Updates NUMBER: 26-08-99F GROUP: Miscellaneous DATE: August, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998-2.5L, 3.9L, 5.2L, 5.9L, 8.0 SFI/Mechanically Injected Diesel Diagnostic Manual Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the Charging System Low Test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 2562 71 Revision to the 5.2/5.9L PCM Wiring Schematic Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 2563 744 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution Powertrain Control Module: All Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions Powertrain Control Module: All Technical Service Bulletins Engine Controls/Fuel System - Service Manual Revisions NUMBER: 26-12-97H GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L, 3.9L, 5.2L, 8.0L Powertrain Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the "No Cam Signal at PCM" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 2572 29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 2573 56 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 2574 58 Revision to the "Fuel Level Sending Unit" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 2575 412 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2576 Powertrain Control Module: Specifications Mounting Screws 1 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2577 Powertrain Control Module: Locations Fig 1 Powertrain Control Module The Powertrain Control Module (PCM) is located under the hood; mounted to the cowling, near the wiper motor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2580 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2581 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2582 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2583 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2584 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2585 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2586 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2587 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2588 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2589 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2590 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2591 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2592 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2593 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2594 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2595 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2596 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2597 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2598 Powertrain Control Module: Connector Views Powertrain Control Module Connectors Powertrain Control Module C1 - Black Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2599 C1 - Black C2 - White C2 - White C3 - Grey Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2600 C3 - Grey Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2601 Powertrain Control Module: Description and Operation SYSTEM OPERATION Powertrain Control Module (PCM) The Powertrain Control Module (PCM) is located in the engine compartment. The ignition system is controlled by the PCM. NOTE: Base ignition timing by rotation of distributor is not adjustable. The PCM opens and closes the ignition coil ground circuit to operate the ignition coil. This is done to adjust ignition timing, both initial (base) and advance, and for changing engine operating conditions. The amount of electronic spark advance provided by the PCM is determined by five input factors: engine coolant temperature, engine rpm, intake manifold temperature, manifold absolute pressure and throttle position. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Module Replacement Powertrain Control Module: Service and Repair Module Replacement Fig 1 Powertrain Control Module REMOVAL 1. Disconnect the negative battery cable at battery. 2. Carefully unplug the three 32-way connectors from PCM. 3. Remove three Powertrain Control Module (PCM) mounting bolts and remove PCM from vehicle. INSTALLATION 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 4 N.m (35 in. lbs.). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary 4. Install three 32-way connectors. 5. Install battery cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Module Replacement > Page 2604 Powertrain Control Module: Service and Repair A Note About PCM Replacement Important Note: If the Powertrain Control Module has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS, Airbag and SKIM modules. In addition, if the vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. For ABS and Airbag Systems: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Airbag modules. For SKIM Theft Alarm: 1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. 3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM (this is required to allow the vehicle to start with the new PCM). 4. If three attempts are made to enter secured access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lock out mode, leave the ignition key in the Run/Start position for one hour. Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Auto Shutdown Relay Connector, Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2608 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2609 Auto Shutdown Relay Connector, Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2610 Automatic Shut Down (ASD) Relay: Description and Operation SYSTEM OPERATION As one of its functions, the (ASD) relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2611 Automatic Shut Down (ASD) Relay: Testing and Inspection Fig. 24 Asd And Fuel Pump Relay Terminals The relay terminal numbers can be found on the bottom of the relay: - Terminal number 30 is connected to battery voltage and can be switched or B+ (hot) at all times. - The center terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the component being operated. - Terminal number 86 is connected to a switched (+) power source. - Terminal number 85 is grounded by the Powertrain Control Module (PCM). TESTING 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. - Resistance value (ohms) should be 75 +/- 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. - Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. - Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). - Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. - Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. - Continuity should now be present between terminals number 87 and 30. - Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 volt power source. If continuity or resistance tests did not pass, replace relay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2612 Automatic Shut Down (ASD) Relay: Service and Repair Fig 2 Power Distribution Center The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC coven 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. - Also check the heights of relay terminal pins at PDC. - Pin height should be same for all pins. - Repair as necessary before installing relay. 2. Push the relay into the connector. 3. Install the relay cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Tray, Battery Tempt Sensor, Engine Wiring Harness, Sensor Harness Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2617 Battery Temperature Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2618 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2619 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry. refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pig-tail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 2622 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. Refer to Starting and Charging/Battery 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Refer to Starting and Charging/Battery Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2626 Camshaft Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2627 Camshaft Position Sensor: Description and Operation SYSTEM OPERATION The camshaft position sensor is located in the distributor on all engines. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2628 Camshaft Position Sensor: Testing and Inspection Camshaft Position Sensor - Typical The camshaft position sensor is located in the distributor on all engines. To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostics Procedures service. To test the sensor only, refer to the following: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Remove engine cover. 2. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. For wire identification. 3. Connect the negative (-) voltmeter lead into the ground wire. For wire identification. 4. Set the voltmeter to the 15 Volt DC scale. 5. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 6. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 7. If voltage is not present, check the voltmeter leads for a good connection. 8. If voltage is still not present, check for voltage at the supply wire. For wire identification. 9. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 10. If voltage is still not present, perform vehicle test using the DRB scan tool. 11. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM. If continuity is not present, repair the harness as necessary c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 12. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2629 Camshaft Position Sensor: Service and Repair The camshaft position sensor is located in the distributor. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove engine cover. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. Crankshaft Position Sensor 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls ECT Sensor Test revisions NUMBER: 26-11-97F GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L/4.0L/5.2L/5.9L SFI Engine Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revisions to the ECT sensor voltage too high test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions > Page 2634 165 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2635 Coolant Temperature Sensor/Switch (For Computer): Specifications Torque 11 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2636 Coolant Temperature Sensor/Switch (For Computer): Locations Generator, A/C Compressor, Elec.CONN, Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2637 Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2638 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Fig 1 Powertrain Control Module To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: 1. Vehicles equipped with air conditioning: a. Disconnect the negative battery cable at battery. b. Remove Jeep/Truck Engine Controller (JTEC) mounting bolts and remove JTEC. Do not disconnect three 32-way connectors from JTEC. Fig. 66 Engine Coolant Temperature Sensor 2. Disconnect wire harness connector from coolant temperature sensor. 3. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2639 Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 4. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 5. Test continuity of the wire harness between the JTEC wire harness connector and the coolant sensor connector terminals. - Refer to Diagrams/connector Views. - Repair the wire harness if an open circuit is indicated. 6. After tests are completed, connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2640 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING COOLANT TEMPERATURE SENSOR. Engine Coolant Temperature Sensor Location The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. 1. Disconnect negative battery cable at battery. 2. Place a small mirror above sensor connector. 3. Disconnect electrical connector from sensor. When removing connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place hook part of tool under connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Partially drain cooling system. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor into intake manifold. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. 5. Connect negative battery cable at battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Mounting Bolts 8 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2644 Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2645 Crankshaft Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2646 Crankshaft Position Sensor: Description and Operation SYSTEM OPERATION Sensor Operation Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. On this engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2647 Crankshaft Position Sensor: Testing and Inspection To perform a complete test of this sensor and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2648 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor - Typical The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. 1. Remove engine cover. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 N.m (70 in.lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications IAT Sensor IAT Sensor Torque 28 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2652 Intake Air Temperature Sensor: Locations Intake Manifold Air TEMPT Sensor, Electrical CONN Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2653 Intake Air TEMPT Sensor CONN Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2654 Intake Air Temperature Sensor: Testing and Inspection Fig. 69 Intake Manifold Air Temperature Sensor 1. Disconnect the wire harness connector from the intake manifold air temperature sensor. Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. Refer to the Coolant Temperature sensor/Intake Air Temperature sensor resistance chart. Replace the sensor if it is not within the range of resistance specified in the chart. 3. Test the resistance of the wire harness. Do this between the Powertrain Control Module (PCM) wire harness connector A-15 and the sensor connector terminal. Also check between PCM connector A-4 to the sensor connector terminal. Repair the wire harness as necessary if the resistance is greater than 1 ohm. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2655 Intake Air Temperature Sensor: Service and Repair Fig 57 Air Temperature Sensor REMOVAL 1. Disconnect electrical connector at sensor. 2. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 N.m (20 ft. lbs.) torque. 2. Install electrical connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Mounting Screws 3 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2659 Manifold Pressure/Vacuum Sensor: Locations Fig. 15 MAP And Throttle Position Sensor Location - Typical Map Sensor, Idle Air Control Motor, Throttle Position Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2660 Map Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2661 Manifold Pressure/Vacuum Sensor: Testing and Inspection Fig 57 Manifold Absolute Pressure Sensor 1. Inspect the rubber L-shaped fitting from the Manifold Absolute Pressure (MAP) sensor to the throttle body. Repair as necessary. CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. Fig 58 Rubber L-Shaped Fitting -- MAP Sensor-to-Throttle Body Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2662 Fig 33 MAP Sensor Connector Terminals -- Typical 2. Test the MAP sensor output voltage at the MAP sensor connector between terminals A and B. With the ignition switch ON and the engine OFF, output voltage should be 4-to-5 volts. The voltage should drop to 1.5-to-2.1 volts with a hot, neutral idle speed condition. 3. Test Powertrain Control Module (PCM) cavity A-27 for the same voltage described above to verify the wire harness condition. Repair as necessary. 4. Test MAP sensor supply voltage at sensor connector between terminals A and C with the ignition ON. The voltage should be approximately 5 volts (+/- 0.5V). Five volts (+/- 0.5V) should also be at cavity A-17 of the PCM wire harness connector. Repair or replace the wire harness as necessary 5. Test the MAP sensor ground circuit at sensor connector terminal-A and PCM connector A-4. Repair the wire harness if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2663 Manifold Pressure/Vacuum Sensor: Service and Repair Fig 86 MAP Sensor Location The Manifold Absolute Pressure (MAP) sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. NOTE: The throttle body must be removed from the intake manifold for MAP sensor removal. REMOVAL 1. Remove air cleaner assembly. 2. Remove throttle body. 3. Remove two MAP sensor mounting bolts (screws). 4. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body 5. Remove rubber L-shaped fitting from MAP sensor. Fig 87 MAP Sensor L-Shaped Rubber Fitting INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 N.m (25 in. lbs.) torque. 4. Install throttle body. 5. Install air cleaner. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions Oil Pressure Sensor: Technical Service Bulletins Engine Controls/Fuel System - Manual Revisions NUMBER: 26-01-99C GROUP: Miscellaneous DATE: January, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Powertrain 2.5L. 3.9L, 5.2L, 5.9L, 8.0 SFI, Mechanical Injected Diesel Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revision to the Table of Contents Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2668 vi Revision to the Trouble Code Test menu Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2669 538 Revision to the Oil Pressure Sensor test 589, 589A through 589F Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2670 589 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2671 589A Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2672 589B Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2673 589C Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2674 589D Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2675 589E Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 2676 589F Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Torque 30 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2682 JTEC O2 Sensor Location Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2683 Oxygen Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2684 Oxygen Sensor: Application and ID Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2685 Oxygen Sensor: Testing and Inspection Fig 6 Heated Oxygen Sensors The upstream O2S sensor is located on the inlet end of the catalytic converter. The downstream O2S sensor is located on the outlet end of the catalytic converter. Each O2S heating element can be tested with an ohmmeter as follows: Disconnect the O2S sensor connector. Connect the ohmmeter test leads across the white wire terminals of the sensor connector. Resistance should be between 4 and 7 ohms. Replace the sensor if the ohmmeter displays an infinity (open) reading. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2686 Oxygen Sensor: Service and Repair Fig 6 Heated Oxygen Sensors NOTE: The O2S sensors are located at the inlet and outlet ends of the catalytic converter. WARNING: The exhaust manifold, exhaust pipes and catalytic converter become very hot during engine operation. Allow engine to cool before removing oxygen sensor. REMOVAL 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. NOTE: Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. INSTALLATION 1. Install the O2S sensor. Tighten to 30 N.m (22 ft. lbs.) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions Throttle Position Sensor: Technical Service Bulletins Fuel System/Engine Controls - Manual Revisions NUMBER: 26-02-99A GROUP: Miscellaneous DATE: February, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revision to the Diagnostic Trouble Codes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2691 45 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2692 46 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2693 47 Revision to the Throttle Position Sensor connector pin outs Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2694 152 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2695 156 Revision to the Fuel System Rich test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2696 316 Revisions to the Throttle Position sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2697 620 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2698 622 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2699 Throttle Position Sensor: Specifications Mounting Screws 7 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2700 Throttle Position Sensor: Locations Map Sensor Throttle Position Sensor, Idle Air Control Motor, Throttle Position Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2701 Throttle Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2702 Throttle Position Sensor: Testing and Inspection The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). - At idle, TPS output voltage should should be greater than 0.350 millivolts and less than 900 millivolts. - At wide open throttle, TPS output voltage must be less than 4.5 volts. - The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. NOTE: For additional testing information and circuit diagnosis see Computers and Control Systems/System Diagnosis/Procedures/Diagnostic Charts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2703 Throttle Position Sensor: Service and Repair Fig 80 TPS Mounting Bolts REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body Fig. 81 Installation INSTALLATION The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2707 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2712 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2713 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2714 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2715 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2716 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2717 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2718 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2719 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2720 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2721 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2722 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2723 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2724 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2725 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2726 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2727 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2728 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2729 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2730 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED AND DISTANCE-PCM INPUT The Vehicle Speed Sensor (VSS) is no longer used for any Dodge truck in the 1998 model year. Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for fuel system and speed control system operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > With Four Wheel Antilock Brakes Vehicle Speed Sensor: Service and Repair With Four Wheel Antilock Brakes REMOVAL 1. Raise and support vehicle. Rear Wheel Speed Sensor 2. Disconnect wire from rear sensor on axle housing. 3. Remove sensor and bracket mounting bolt and remove sensor and bracket. INSTALLATION 1. Secure sensor wire to rear brake hose with clips provided. 2. Install sensor and mounting bracket in axle housing. Install mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Connect wire to sensor and secure wire to mounting bracket. 4. Remove support and lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > With Four Wheel Antilock Brakes > Page 2733 Vehicle Speed Sensor: Service and Repair With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 0-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions Throttle Position Sensor: Technical Service Bulletins Fuel System/Engine Controls - Manual Revisions NUMBER: 26-02-99A GROUP: Miscellaneous DATE: February, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revision to the Diagnostic Trouble Codes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2738 45 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2739 46 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2740 47 Revision to the Throttle Position Sensor connector pin outs Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2741 152 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2742 156 Revision to the Fuel System Rich test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2743 316 Revisions to the Throttle Position sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2744 620 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2745 622 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2746 Throttle Position Sensor: Specifications Mounting Screws 7 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2747 Throttle Position Sensor: Locations Map Sensor Throttle Position Sensor, Idle Air Control Motor, Throttle Position Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2748 Throttle Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2749 Throttle Position Sensor: Testing and Inspection The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). - At idle, TPS output voltage should should be greater than 0.350 millivolts and less than 900 millivolts. - At wide open throttle, TPS output voltage must be less than 4.5 volts. - The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. NOTE: For additional testing information and circuit diagnosis see Computers and Control Systems/System Diagnosis/Procedures/Diagnostic Charts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2750 Throttle Position Sensor: Service and Repair Fig 80 TPS Mounting Bolts REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body Fig. 81 Installation INSTALLATION The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2754 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2759 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2760 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2761 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2762 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2763 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2764 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2765 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2766 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2767 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2768 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2769 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2770 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2771 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2772 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2773 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2774 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2775 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2776 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2777 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED AND DISTANCE-PCM INPUT The Vehicle Speed Sensor (VSS) is no longer used for any Dodge truck in the 1998 model year. Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for fuel system and speed control system operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > With Four Wheel Antilock Brakes Vehicle Speed Sensor: Service and Repair With Four Wheel Antilock Brakes REMOVAL 1. Raise and support vehicle. Rear Wheel Speed Sensor 2. Disconnect wire from rear sensor on axle housing. 3. Remove sensor and bracket mounting bolt and remove sensor and bracket. INSTALLATION 1. Secure sensor wire to rear brake hose with clips provided. 2. Install sensor and mounting bracket in axle housing. Install mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Connect wire to sensor and secure wire to mounting bracket. 4. Remove support and lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > With Four Wheel Antilock Brakes > Page 2780 Vehicle Speed Sensor: Service and Repair With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 0-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service Precautions > Customer Safety Information Catalytic Converter: Customer Safety Information CATALYTIC CONVERTER The catalytic converter routinely reaches operating temperatures of 650° C (1200° F) and will stay hot for some time after the engine has been shut off. Do NOT park the vehicle over any object or material that could ignite (i.e. dry leaves, cardboard, puddles of oil, or other combustibles). CARBON MONOXIDE Exhaust gas contains toxic carbon monoxide. Do not run the engine in confined areas or breathe concentrated exhaust gases. Breathing exhaust gases may cause loss of consciousness or death. EXHAUST SYSTEM LEAKS Repair any leaks in the exhaust system as soon as possible. Hot gases escaping from the leak can ignite flammable materials and may set the vehicle on fire. Also exhaust may circulate through the passenger compartment causing throat, sinus, and eye irritation, light headedness, headaches, and increased irritability, especially while driving with windows closed. FUEL ODORS/EXCESSIVE EMISSIONS Be alert for fuel odors and excessive tailpipe emissions (black smoke etc...). These indicate a problem that should be corrected as soon as possible (excessive emissions can ruin oxygen sensors, catalytic converters, and other expensive emission components). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service Precautions > Customer Safety Information > Page 2786 Catalytic Converter: Technician Safety Information WHEN SERVICING ANY VEHICLE OBSERVE THE FOLLOWING CAUTIONS: 1. Always wear appropriate eye protection. 2. Block the drive wheels as a safety routine before beginning any service with the vehicle on the ground. 3. Never work under a vehicle supported only by a jack. Use jackstands on a flat and level hard surface for safe support. 4. Use caution when working near the catalytic converter to prevent the possibility of burns. The temperatures within the converter can exceed 1200°F. 5. Exercise care when working with spring or tension loaded fasteners such as E-clips, or snap rings, careless removal can cause personal injury. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service Precautions > Customer Safety Information > Page 2787 Catalytic Converter: Vehicle Damage Warnings CATALYTIC CONVERTERS On vehicles equipped with catalytic converters, the following conditions must be observed: - Use only "UNLEADED FUEL". - Avoid running out of fuel. - In case of poor engine operation (misfiring), avoid driving the vehicle and correct the problem as soon as possible. - Do not disconnect any spark plug wires with the engine running. - Avoid push starting the vehicle. - If running on a dynamometer, make sure the catalytic converter is well ventilated. - Use caution when working near the catalytic converter to prevent the possibility of burns. OXYGEN SENSORS AND SILICONE Do not use silicone based products on an oxygen sensor equipped vehicle to avoid damaging the sensor. COMPRESSION TESTING When performing a compression test, remove the fuel pump relay fuse, and disconnect power to the ignition (This will stop fuel flow to the injectors and prevent engine from starting). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service Precautions > Page 2788 Catalytic Converter: Description and Operation CONSTRUCTION The stainless steel catalytic converter body is designed to last the life of the vehicle. HEAT Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also, inspect all other components of the exhaust system for heat damage. CAUTION: Unleaded gasoline must be used to avoid contaminating the catalyst core. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Removal and Installation Catalytic Converter: Service and Repair Removal and Installation CATALYTIC CONVERTER WITH PIPES REMOVAL 1. Raise and support vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove clamps and nuts. 4. Remove the catalytic converter. INSTALLATION 1. Assemble converter and clamps loosely in place. 2. Install the exhaust pipe onto exhaust manifolds, tighten 34 Nm (25 ft. lbs.). 3. Tighten all clamp nuts to 43 Nm (32 ft. lbs.) torque. 4. Lower the vehicle. 5. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. A minimum of 25.4 mm (1.0 in.) is required between exhaust system components and body/frame parts. Adjust the alignment, if needed. CLEANING Clean ends of pipes and muffler to assure a good seal at mating surfaces. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Removal and Installation > Page 2791 Catalytic Converter: Service and Repair Cleaning and Inspection CATALYTIC CONVERTER INSPECTION Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of overheating. If the converter has a heat shield attached make sure it is not bent or loose. WARNING: UNLEADED FUEL MUST BE USED TO PREVENT BLOCKAGE OR CONTAMINATION TO THE CATALYST CORE. If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate a damaged core. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Purge Solenoid,mounting Bracket, Left Front Wheel-house,LDP.LDP Filter Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2796 Evaporative Solenoid Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2797 Canister Purge Solenoid: Description and Operation EVAP Purge Solenoid And LDP DESCRIPTION All engines use a duty cycle EVAP canister purge solenoid. The solenoid regulates the rate of vapor flow from the EVAP canister to the throttle body. The Powertrain Control Module (PCM) operates the solenoid. OPERATION During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. The PCM deenergizes the solenoid during open loop operation. The engine enters closed loop operation after it reaches a specified temperature and the time delay ends. During closed loop operation, the PCM energizes and de-energizes the solenoid 5 or 10 times per second, depending upon operating conditions. The PCM varies the vapor flow rate by changing solenoid pulse width. Pulse width is the amount of time the solenoid energizes. The PCM adjusts solenoid pulse width based on engine operating condition. CIRCUIT OPERATION The Powertrain Control Module (PCM) operates the EVAP/Purge solenoid by providing a ground path on circuit K52. Circuit K52 connects to PCM cavity C20. Circuit F18 supplies battery voltage to the EVAP/Purge solenoid. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2798 Canister Purge Solenoid: Service and Repair EVAP Purge Solenoid And LDP REMOVAL The duty cycle purge solenoid is attached to a bracket mounted to the left-inner wheelhouse (fender). NOTE: The purge solenoid shown in is for vehicles equipped with a Leak Detection Pump (LDP). If not equipped with an LDP, the location/mounting is slightly different. 1. Disconnect electrical wiring connector at solenoid. 2. Disconnect vacuum harness at solenoid. 3. Remove solenoid from support bracket. INSTALLATION 1. Install solenoid assembly to support bracket. 2. Connect vacuum harness. 3. Connect wiring connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Canister Mounting Nuts, Driver Door Well, EVAP Canister, Bracket Bolts Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2802 Evaporative Emission Control Canister: Description and Operation EVAP Canister DESCRIPTION Two, maintenance free, EVAP canisters are used. The canisters are mounted to a common bracket located under the left side of vehicle behind the drivers door well. The EVAP canisters are filled with granules of an activated carbon mixture. OPERATION Fuel vapors entering the EVAP canisters are absorbed by the charcoal granules. Fuel tank pressure vents into tile EVAP canisters. Fuel vapors are temporarily held in the canisters until they can be drawn into the intake manifold. The duty cycle EVAP canister purge solenoid allows the EVAP canisters to be purged at predetermined times and at certain engine operating conditions. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2803 Evaporative Emission Control Canister: Service and Repair EVAP Canister Two EVAP canisters are used. The canisters are mounted to a common bracket located under the left side of vehicle behind the drivers door well. REMOVAL 1. Remove 2 bolts retaining canister bracket assembly to body. 2. Carefully lower the assembly and remove fuel tubes/lines at each EVAP canister. Note location of tubes/lines before removal for easier installation. 3. Remove canister mounting nuts. INSTALLATION 1. Position each canister to bracket and install nuts Tighten to 8 Nm (71 in. lbs.) torque. 2. Install fuel tubes/lines to canister. 3. Position assembly to body. Note locating ears at upper part of mounting bracket. Position these ears into notches on body. 4. Install 2 bracket bolts and tighten to 10 Nm (95 in. lbs.) torque. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Locations EVAP System Test Port, Power Brake Booster, Steering Column Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > EVAP System - Leak Detection Pump Misdiagnosis Leak Detection Pump: Technical Service Bulletins EVAP System - Leak Detection Pump Misdiagnosis NUMBER: 18-01-00 GROUP: Vehicle Performance DATE: Feb. 4, 2000 SUBJECT: Misdiagnosed Leak Detection Pump Systems With DTC P1494, P0442, P0455, OR P0456 MODELS: 1997 - 2000 (AB) Ram Van 1997 - 2000 (AN) Dakota 1997 - 2000 (BR/BE) Ram truck 1998 - 2000 (DN) Durango 1997 - 2000 (FJ) Avenger/Sebring/Talon 1997 - 2000 (JA) Cirrus/Stratus/Breeze 1997 - 2000 (JX) Sebring Convertible 1997 - 2000 (LH) Concorde/Intrepid/LHS/3OOMNision 1997 - 2000 (NS) Town & Country/CaravanNoyager 1997 2000 (PL) Neon 1997 - 2000 (PR) Prowler 1997 - 2000 (SR) ViperNiper GIS 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1997 - 1998 (ZJ) GrandCherokee DISCUSSION: During evaporative system diagnosis, Leak Detection Pumps have mistakenly been replaced. A thorough inspection for pinched, kinked, or disconnected supply vacuum lines (as currently listed in the Powertrain Diagnostic Procedures) is a critical step in diagnosing DTC P1494 (LDP SW OR MECHANICAL FAULT). Additionally, the other evaporative leak faults (DTC P0442 SMALL LEAK, P0455 - LARGE LEAK, and P0456 - VERY SMALL LEAK) should have the supply vacuum lines examined for pinches or kinks prior to any LDP component replacement. The supply vacuum lines should be checked from the engine compartment all the way to the fuel tank, including the LDP and purge system. NOTE: VERIFY ALL RELATED SUPPLY VACUUM LINE ROUTINGS FOR PINCHES, KINKS, OR DISCONNECTION'S BEFORE REPLACING LDP SYSTEM COMPONENTS. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2811 Purge Solenoid, Mounting Bracket, Left Front Wheel-House, LDP Filter Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2812 LDP Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2813 Leak Detection Pump: Description and Operation Leak Detection Pump (LDP) Operation And Diagnosis This bulletin describes the theory of operation for the leak detection system. In addition, information is provided for each of the Diagnostic Trouble Codes (DTC's) as follows: P0442-EVAP LEAK MONITOR 0.040" LEAK DETECTED P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED P0456-EVAP LEAK MONITOR 0.020" LEAK DETECTED P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND P1494-LEAK DETECTION PUMP SW OR MECHANICAL FAULT P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT INTRODUCTION The evaporative emission system is designed to prevent the escape of fuel vapors from the fuel system. Leaks in the system, even small ones, can allow fuel vapors to escape into the atmosphere. Government regulations require on-board testing to make sure that the evaporative (EVAP) system is functioning properly. The leak detection system tests for EVAP system leaks and blockage. It also performs self-diagnostics. During self-diagnostics, the Powertrain Control Module (PCM) first checks the Leak Detection Pump (LDP) for electrical and mechanical faults. If the first checks pass, the PCM then uses the LDP to seal the vent valve and pump air into the system to pressurize it. If a leak is present, the PCM will continue pumping the LDP to replace the air that leaks out. The PCM determines the size of the leak based on how fast/long it must pump the LDP as it tries to maintain pressure in the system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2814 EVAP LEAK DETECTION SYSTEM COMPONENTS Service Port: Used with special tools like the Miller Evaporative Emissions Leak Detector (EELD) to test for leaks in the system. EVAP Purge Solenoid: The PCM uses the EVAP purge solenoid to control purging of excess fuel vapors stored in the EVAP canister. It remains closed during leak testing to prevent loss of pressure. EVAP Canister The EVAP canister stores fuel vapors from the fuel tank for purging. EVAP Purge Orifice: Limits purge volume. EVAP System Air Filter: Provides air to the LDP for pressurizing the system. It filters out dirt while allowing a vent to atmosphere for the EVAP system. Leak Detection Pump (LDP) Components The main purpose of the LDP is to pressurize the fuel system for leak checking. It closes the EVAP system vent to atmospheric pressure so the system can be pressurized for leak testing. The diaphragm is powered by engine vacuum. It pumps air into the EVAP system to develop a pressure of about 7.5' H20(1/4) psi. A reed switch in the LDP allows the PCM to monitor the position of the LDP diaphragm. The PCM uses the reed switch input to monitor how fast the LDP is pumping air into the EVAP system. This allows detection of leaks and blockage. The LDP assembly consists of several parts. The solenoid is controlled by the PCM, and it connects the upper pump cavity to either engine vacuum or atmospheric pressure. A vent valve closes the EVAP system to atmosphere, sealing the system during leak testing. The pump section of the LDP consists of a diaphragm that moves up and down to bring air in through the air filter and inlet check valve, and pump it out through an outlet check valve into the EVAP system. The diaphragm is pulled up by engine vacuum, and pushed down by spring pressure, as the LDP solenoid turns on and off. The LDP also has a magnetic reed switch to signal diaphragm position to the PCM. When the diaphragm is down, the switch is closed, which sends a 12 V (system voltage) signal to the PCM. When the diaphragm is up, the switch is open, and there is no voltage sent to the PCM. This allows the PCM to monitor LDP pumping action as it turns the LDP solenoid on and off. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2815 LDP AT REST (NOT POWERED) When the LDP is at rest (no electrical/vacuum) the diaphragm is allowed to drop down if the internal (EVAP system) pressure is not greater than the return spring. The LDP solenoid blocks the engine vacuum port and opens the atmospheric pressure port connected through the EVAP system air filter. The vent valve is held open by the diaphragm. This allows the canister to see atmospheric pressure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2816 DIAPHRAGM UPWARD MOVEMENT When the PCM energizes the LDP solenoid, the solenoid blocks the atmospheric port leading through the EVAP air filter and at the same time opens the engine vacuum port to the pump cavity above the diaphragm. The diaphragm moves upward when vacuum above the diaphragm exceeds spring force. This upward movement closes the vent valve. It also causes low pressure below the diaphragm, unseating the inlet check valve and allowing air in from the EVAP air filter. When the diaphragm completes its upward movement, the LDP reed switch turns from closed to open. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2817 DIAPHRAGM DOWNWARD MOVEMENT based on reed switch input, the PCM de-energizes the LDP solenoid, causing it to block the vacuum port, and open the atmospheric port. This connects the upper pump cavity to atmosphere through the EVAP air filter. The spring is now able to push the diaphragm down. The downward movement of the diaphragm closes the inlet check valve and opens the outlet check valve pumping air into the evaporative system. The LDP reed switch turns from open to closed, allowing the PGM to monitor LDP pumping (diaphragm up/down) activity. During the pumping mode, the diaphragm will not move down far enough to open the vent valve The pumping cycle is repeated as the solenoid is turned on and off. When the evaporative system begins to pressurize, the pressure on the bottom of the diaphragm will begin to oppose the spring pressure, slowing the pumping action. The PCM watches the time from when the solenoid is de-energized, until the diaphragm drops down far enough for the reed switch to change from opened to closed. If the reed switch changes too quickly, a leak may be indicated. The longer it takes the reed switch to change state, the tighter the evaporative system is sealed. If the system pressurizes too quickly, a restriction somewhere in the EVAP system may be indicated. PUMPING ACTION During portions of this test, the PCM uses the reed switch to monitor diaphragm movement. The solenoid is only turned on by the PCM after the reed switch changes from open to closed, indicating that the diaphragm has moved down. At other times during the test, the PCM will rapidly cycle the LDP solenoid on and off to quickly pressurize the system. During rapid cycling, the diaphragm will not move enough to change the reed switch state. In the state of rapid cycling, the PCM will use a fixed time interval to cycle the solenoid. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2818 Leak Detection Pump: Testing and Inspection ENABLING CONDITIONS TO RUN EVAP LEAK DETECTION TEST NOTE: The following values are approximate and vehicle specific. Use the values seen in pre test/monitor test screen on the DRB III. See TSB 25-02-98 for more detail 1. Cold start: with ambient temperature (obtained from modeling the inlet air temperature sensor on passenger vehicles and the battery temperature sensor on Jeep & truck vehicles) between 4C° (40° F) and 32° C (90° F) for 0.040 leak. Between 4C° (40° F) and 29° C (85° F) for 0.020 leak. 2. Engine coolant temperature within:-12° to -8°C (10° to 18°F) of battery/ambient. 3. Battery voltage between 10 and 15 volts. NOTE: If battery voltage drops below 10 volts for more than 5 seconds during engine cranking, the EVAP leak detection test will not run. 4. Low fuel warning light off (fuel level must be between 15% and 85% for 0.040 leak and 30% and 85% for 0.020 leak). 5. MAP sensor reading 22 in Hg or above (This is the manifold absolute pressure, not vacuum). 6. No engine stall during test. If the system does not pass the EVAP Leak Detection Test, the following DTCs may be set: - P0442 - EVAP LEAK MONITOR 0.040" LEAK DETECTED - P0455 - EVAP LEAK MONITOR LARGE LEAK DETECTED - P0456 - EVAP LEAK MONITOR 0.020" LEAK DETECTED - P1486 - EVAP LEAK MON PINCHED HOSE FOUND - P1494 - LEAK DETECTION PUMP SW OR MECH FAULT - P1495 - LEAK DETECTION PUMP SOLENOID CIRCUIT A DTC will not be set if a one-trip fault is set or if MIL is illuminated for any of the following: - Purge Solenoid Electrical Fault - All Engine Controller Self Test Faults - All Cam And/or Crank Sensor Fault - All Map Sensor Faults - Ambient/battery Temperature Sensor Electrical Faults - All Coolant Sensor Faults - All TPS Faults - LDP Pressure Switch Fault - EGR Solenoid Fault - All Injector Faults - Baro Our Of Range - Vehicle Speed Faults - LDP Solenoid Circuit Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2819 Figure 6 EVAP leak detection test sequence When the ignition key is turned to "ON" the LDP diaphragm should be in the down position and the LDP reed switch should be closed. If the EVAP system has residual pressure, the LDP diaphragm may be up. This could result in the LDP reed switch being open when the key is turned to "ON" and a P1494 fault could be set because the PCM is expecting the reed switch to be closed. After the key is turned "ON", the PCM immediately tests the LDP solenoid circuit for electrical faults. If a fault is detected, DTC P1495 will set, the MIL will illuminate, and the remaining EVAP Leak Detection Test is canceled. NOTE: If battery temperature is not within range, or if the engine coolant temperature is not within a specified range of the battery temperature, the PCM will not run tests for DTC P1494, P1486, P0442, P0455 and P0441. These temperature calibrations may be different between models. FIGURE 6 SECTION 2 If DTC P1495 is not set, the PCM will check for DTC P1494. If the LDP reed switch was closed when the key was turned to "ON", the PCM energizes the LDP solenoid for up to 8 seconds and monitors the LDP switch. As the LDP diaphragm is pulled up by engine vacuum, the LDP reed switch should change from closed to open. If it does not, the PCM sets a temporary fault (P1494) in memory, and waits until the next time the Enabling Conditions are met to run the test again. If this is again detected, P1494 is stored and the MIL is illuminated. If the problem is not detected during the next enabling cycle, the temporary fault will be cleared. However, if the PCM detects the reed switch open when the key is turned to "ON", the PCM must determine if this condition is due to residual pressure in the EVAP system, or an actual fault. The PCM stores information in memory on EVAP system purging from previous engine run or drive cycles. If little or no purging took place, residual pressure could be holding the LDP diaphragm up, causing the LDP switch to be open. Since this is not a malfunction, the PCM cancels the EVAP Leak Detection Test without setting the temporary fault. If there was sufficient purging during the previous cycle to eliminate EVAP system pressure, the PCM judges that this is a malfunction and sets a temporary fault in memory. The next time that the Enabling Conditions are met, the test will run again. If the fault is again detected, the MIL will Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2820 illuminate and DTC 1494 will be stored. If the fault is not detected, the temporary fault will be cleared. FIGURE 6 SECTION 3 If no fault has been detected so far, the PCM begins testing for possible blockage in the EVAP system between the LDP and the fuel tank. This is done by monitoring the time required for the LDP to pump air into the EVAP system during two to three pump cycles. If no blockage is present, the LDP diaphragm is able to quickly pump air out of the LDP each time the PCM turns oft the LDP solenoid. If a blockage is present, the PCM detects that the LDP takes longer to complete each pump cycle. If the pump cycles take longer than expected (approximately 6 to 10 seconds) the PCM will suspect a blockage. On the next drive when Enabling Conditions are met, the test will run again. If blockage is again detected, P1486 is stored, and the MIL is illuminated. FIGURE 6 SECTION 4 After the LDP blockage tests are completed, the PCM then tests for EVAP system leakage. First, the PCM commands the LDP to rapidly pump for 20 to 50 seconds (depending on fuel level) to build pressure in the EVAP system. This evaluates the system J18-24-0 to see if it can be sufficiently pressurized. This evaluation (rapid pump cycling) may occur several times prior to leak checking. The LDP reed switch does not close and open during rapid pumping because the diaphragm does not travel through its full range during this part of the test. FIGURE 6 SECTION 5 Next, the PCM performs one or more test cycles by monitoring the time required for the LDP reed switch to close (diaphragm to drop) after the LDP solenoid is turned off. If the switch does not close, or closes after a long delay, it means that the system does not have any significant leakage and the EVAP Leak Detection Test is complete. However, if the LDP reed switch closes quickly, there may be a leak or the fuel level may be low enough that the LDP must pump more to finish pressurizing the EVAP system. In this case, the PCM will rapidly pump the LDP again to build pressure in the EVAP system, and follow that by monitoring the time needed for several LDP test cycles. This process of rapid pumping followed by several LDP test cycles may repeat several times before the PCM judges that a leak is present. When leaks are present, the LDP test cycle time will be inversely proportional to the size of the leak. The larger the leak, the shorter the test cycle time. The smaller the leak, the longer the test cycle time. DTC's may be set when a leak as small as 0.5 mm (0.020") diameter is present. If the system detects a leak, a temporary fault will be stored in PCM memory. The time it takes to detect a .020, .040, or Large leak is based on calibrations that vary from model to model. The important point to remember is if a leak is again detected on the next EVAP Leak Detection Test, the MIL will illuminate and a DTC will be stored based on the size of leak detected. If no leak is detected during the next test, the temporary fault will be cleared. DIAGNOSTIC TIPS During diagnosis, you can compare the LDP solenoid activity with the monitor sequence in Figure 6. If the PCM detects a problem that could set a DTC, the testing is halted and LDP solenoid activity will stop. As each section of the test begins, it indicates that the previous section passed successfully. By watching to see which tests complete, you can see if any conditions are present that the PCM considers abnormal. For example, if the LDP solenoid is energized for the test cycles to test for blockage (P1486), it means that the LDP has already passed its test for P1494. Then, if the PCM detects a possible blockage, it will set a temporary fault without turning on the MIL and continue the leak portion of the test. However, the PCM will assume that the system is already pressurized and skip the rapid pump cycles. Always diagnose leaks, if possible, before disconnecting connections. Disconnecting connections may mask a leak condition. Keep in mind that if the purge solenoid seat is leaking, it could go undetected since the leak would end up in the intake manifold. Disconnect the purge solenoid at the manifold when leak checking. In addition, a pinched hose fault (P1486) could set if the purge solenoid does not purge the fuel system properly (blocked seat). The purge solenoid must vent the fuel system prior to the LDP system test. If the purge solenoid cannot properly vent the system the LDP cannot properly complete the test for P1486 and this fault can set due to pressure being in the EVAP system during the test sequence. Multiple actuation's of the DRB Ill® Leak Detection Pump (LDP) Monitor Test can hide a 0.020 leak because of excess vapor generation. Additionally, any source for additional vapor generation can hide a small leak in the EVAP system. Excess vapor generation can delay the fall of the LDP diaphragm thus hiding the small leak. An example of this condition could be bringing a cold vehicle into a warm shop for testing or high ambient temperatures. Fully plugged and partially plugged underhood vacuum lines have been known to set MIL conditions. P1494 and P0456 can be set for this reason. Always, thoroughly, check plumbing for pinches or blockage before condemning components. TEST EQUIPMENT The Evaporative Emission Leak Detector (EELD) Miller Special Tool 8404 is capable of visually detecting leaks in the evaporative system and will take Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2821 the place of the ultrasonic leak detector 6917A. The EELD utilizes shop air and a smoke generator to visually detect leaks down to 0.020 or smaller. The food grade oil used to make the smoke includes an UV trace dye that will leave telltale signs of the leak under a black light. This is helpful when components have to be removed to determine the exact leak location. For detailed test instructions, follow the operators manual packaged with the EELD. IMPORTANT Be sure that the PCM has the latest software update. Reprogram as indicated by any applicable Technical Service Bulletin. After LDP repairs are completed, verify the repair by running the DRB Ill® Leak Detection Pump (LDP) Monitor Test as described in Technical Service Bulletin 18-12-99. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2822 Leak Detection Pump: Service and Repair Leak Detection Pump Mounting The LDP, LDP filter and EVAP purge solenoid are attached to a common bracket. The assembly is located in the engine compartment on the left-inner wheelhouse (fender). The LDP and LDP filter are replaced (serviced) as one unit. REMOVAL 1. Disconnect negative battery cable at battery 2. Disconnect electrical connector at duty cycle purge solenoid. 3. Remove duty cycle purge solenoid from bracket. 4. Disconnect electrical connector at LDP. 5. Carefully remove vapor/vacuum lines at LDP. 6. Remove two bracket mounting bolts. 7. Remove LDP, LDP filter and bracket assembly from vehicle. 8. Remove 3 LDP mounting screws and remove LDP from bracket. 9. Remove LDP filter mounting bolt. INSTALLATION 1. Install LDP filter to bracket. Tighten mounting bolt to 7 Nm (65 in. lbs.) torque. 2. Install LDP to bracket. Tighten screws to 1 Nm (11 in. lbs.) torque. 3. Install LDP and bracket assembly to body and install mounting bolts. Tighten bolts to 7 Nm (65 in. lbs.) torque. 4. Carefully install vapor/vacuum lines to LDP. The vapor/vacuum lines and hoses must be firmly connected. Check the vapor/vacuum lines at the LDP, LDP filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 5. Connect electrical connector to LDP. 6. Install duty cycle purge solenoid to bracket. 7. Connect negative battery cable to battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Filter > Component Information > Description and Operation Crankcase Filter: Description and Operation Fig 9 Crankcase Breather Filter CRANKCASE BREATHER/FILTER The crankcase breather/filter (Fig. 9) is located on the cylinder head (valve) cover. The filter may be cleaned by washing it thoroughly in kerosene or an equivalent. Filter must be thoroughly drained. More frequent service may be necessary for vehicles operated extensively on short run, stop and go, extended engine idle service or extreme dust conditions. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage NO: 14-03-98 GROUP: Fuel DATE: May 1, 1998 SUBJECT: Fuel Pressure Gauge Adapter Usage MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) DISCUSSION: Currently, four different fuel pressure adapters are required, depending on application, to attach a fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications Fuel Pressure: Pressure, Vacuum and Temperature Specifications Fuel Pressure Engine at curb idle ............................................................................................................................... ........................................ 339 ± 34 kPa (49.2 ± 5 psi) Pressure Leakdown (fuel pump not engaged) ................................................................................................................. Not fall below 30 psi for 5 minutes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2834 Fuel Pressure: Capacity Specifications NOTE: Before performing this test, verify fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. - Refer to the Fuel Pressure Release Procedure. 2. Disconnect the fuel supply line at fuel rail. - Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. - Insert other end of Adaptor Tool hose into a graduated container. 4. Remove the fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. - Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. - Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test Fig 9 Connecting Adaptor Tool -- Typical Fig. 8 Installing Adapter Tool And Pressure Gauge NOTE: Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: Fuel pressure bleeding past a fuel injector(s). - Fuel pressure bleeding past the check valve in the fuel pump module. 1. Disconnect the fuel inlet line at fuel rail. - On some engines, air cleaner housing removal may be necessary before fuel line disconnection. 2. Connect the appropriate Fuel Line Pressure Test Adapter Tool (number 6539, 6631, 6541 or 6923) between the disconnected fuel line and fuel rail (Fig. 9) or (Fig. 10). 3. Connect the 0-414 kPa (0-60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. - The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 4. Start engine and bring to normal operating temperature. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2837 5. Observe test gauge. Normal operating pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). 6. Shut engine off. 7. Pressure should not fall below 30 psi for five minutes. 8. If pressure falls below 30 psi, it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 9. Again, start engine and bring to normal operating temperature. 10. Shut engine off. 11. Testing for fuel injector or fuel rail leakage: - Clamp off the rubber hose portion of Adaptor Tool between the fuel rail and the test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a fuel injector or the fuel rail is leaking. 12. Testing for fuel pump check valve, filter/regulator check valve or fuel tube/line leakage: - Clamp off the rubber hose portion of Adaptor Tool between the vehicle fuel line and test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a leak may be found at a fuel tube/line. - If no leaks are found at fuel tubes or lines, one of the check valves in either the electric fuel pump or filter/ regulator may be leaking. NOTE: A quick loss of pressure usually indicates a defective check valve in the filter/regulator. A slow loss of pressure usually indicates a defective check valve in the electric fuel pump. The electric fuel pump is not serviced separately -- Replace the fuel pump module assembly. The filter/ regulator may be replaced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/installation for additional information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2838 Fuel Pressure: Testing and Inspection Fuel Pressure Test Fuel Pressure Test Gauge NOTE: Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test, fuel pump amperage test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow hack into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. WARNING: The fuel system is under constant fuel pressure even with the engine off. Before disconnecting fuel line at fuel rail, this pressure must be released. Refer to the fuel system pressure release procedure. NOTE: To perform this test you will need to remove the engine cover. 1. Remove the protective cap at the fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port pressure fitting on the fuel rail. 2. Start and warm the engine and note pressure gauge reading. Fuel pressure should be 3.39 kPa +/- 34 kPa (49.2 psi +/- 5 psi) at idle. 3. If engine runs but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, replace fuel pump module assembly. Refer to Fuel Pump Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel filter/fuel pressure regulator. Certain filter/regulators may be serviced separately and some require the replacement of the fuel pump module assembly Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2839 Fuel Pressure: Testing and Inspection Fuel Pump Amperage Test This amperage (current draw) test is to be done in conjunction with the Fuel Pump Pressure Test, Fuel Pump Capacity Test and Fuel Pressure Leak Down Test. Before performing the amperage test, be sure the temperature of the fuel tank is above 50° F (10° C). The DRB Scan Tool along with the DRB Low Current Shunt (LCS) adapter and its test leads will be used to check fuel pump amperage specifications. Low Current Shunt Adapter 1. Obtain LCS adapter. 2. Plug cable from LCS adapter into DRB scan tool at SET 1 receptacle. 3. Plug DRB into vehicle 16-way connector (data link connector). 4. Connect (-) and (+) test cable leads into LCS adapter receptacles. Use 10 amp (10A +) receptacle and common (-) receptacles. 5. Gain access to MAIN MENU on DRB screen. 6. Press DVOM button on DRB. 7. Using left/right arrow keys, highlight CHANNEL 1 function on DRB screen. 8. Press ENTER three times. 9. Using up/down arrow keys, highlight RANGE on DRB screen (screen will default to 2 amp scale). 10. Press ENTER to change 2 amp scale to 10 amp scale. This step must be done to prevent damage to DRB scan tool or LCS adapter (blown fuse). 11. Remove cover from Power Distribution Center (PDC). 12. Remove fuel pump relay from PDC. Refer to label on PDC cover for relay location. WARNING: BEFORE PROCEEDING TO NEXT STEP, NOTE THE FUEL PUMP WILL BE ACTIVATED AND SYSTEM PRESSURE WILL BE PRESENT. THIS WILL OCCUR AFTER CONNECTING TEST LEADS FROM LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES. THE FUEL PUMP WILL OPERATE EVEN WITH IGNITION KEY IN OFF POSITION. BEFORE ATTACHING TEST LEADS, BE SURE ALL FUEL LINES AND FUEL SYSTEM COMPONENTS ARE CONNECTED. CAUTION: To prevent possible damage to the vehicle electrical system and LCS adapter, the test leads must be connected into relay cavities exactly as shown in following steps. Depending upon vehicle model, year or engine configuration, three different types of relays may be used: Type-1, type-2 and type-3. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2840 Starter Relay 13 If equipped with type-1 relay, attach test leads from LCS adapter into PDC relay cavities number 30 and 87. For location of these cavities, refer to numbers stamped to bottom of relay. Type-2 Relay 14. If equipped with type-2 relay, attach test leads from LCS adapter into PDC relay cavities number 30 and 87. For location of these cavities, refer to numbers stamped to bottom of relay. Type-3 Relay 15. If equipped with type-3 relay, attach test leads from LCS adapter into PDC relay cavities number 3 and 5. For location of these cavities, refer to numbers stamped to bottom of relay. 16. When LCS adapter test leads are attached into relay cavities, fuel pump will be activated. Determine fuel pump amperage on DRB screen. Amperage should be below 10.0 amps. If amperage is below 10.0 amps, and specifications for the Fuel Pump Pressure, Fuel Pump Capacity and Fuel Pressure Leak Down tests were met, the fuel pump module is OK. 17. If amperage is more than 10.0 amps, replace fuel pump module assembly The electric fuel pump is not serviced separately. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2841 18. Disconnect test leads from relay cavities immediately after testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2842 Fuel Pressure: Testing and Inspection Fuel Pump Capacity Test NOTE: Before performing this test, verify fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. - Refer to the Fuel Pressure Release Procedure. 2. Disconnect the fuel supply line at fuel rail. - Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. - Insert other end of Adaptor Tool hose into a graduated container. 4. Remove the fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. - Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. - Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair NOTE: Use following procedure if fuel rail is or is not equipped with fuel pressure test port. 1. Remove fuel fill cap. 2. The fuel filler tube contains a spring-loaded flap (door) located below fuel fill cap. The flap is used as a secondary way of sealing fuel tank if fuel fill cap has not been properly tightened. It is part of EVAP monitor system when vehicle is equipped with a Leak Detection Pump (LDP). The vehicle may be equipped with flap installed into fuel filler tube even though vehicle is not equipped with LDP and EVAP monitor system. Place a nonmetallic object into fuel fill tube and press on flap to relieve any tank pressure. 3. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 7. Unplug connector from any injector. 8. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 9. Connect other end of jumper wire to positive side of battery. 10. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 11. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 12. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 13. Disconnect quick-connect fitting at fuel rail. 14. Return fuel pump relay to PDC. 15. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ......................................................... 500 to 900 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 2849 Idle Speed: Testing and Inspection The following test procedure has been developed to check throttle body calibrations for correct idle conditions. The procedure should be used to diagnose the throttle body for conditions that may cause idle problems. This procedure should be used only after normal diagnostic procedures have failed to produce results that indicate a throttle body related problem. Be sure to check for proper operation of the idle air control motor before performing this test. Fig. 73 Fixed Orifice Tool A special fixed orifice tool (number 6714) must be used for the following test. 1. Start the engine and bring to operating temperature. Be sure all accessories are off before performing this test. 2. Shut off the engine and remove the air cleaner element housing. Fig. 74 Install Orifice Tool 3. Disconnect the vacuum line at the PCV valve. 4. Install the 0.185 inch orifice tool (number 6714) into the disconnected vacuum line in place of the PCV valve. Fig. 75 Idle Purge Line Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 2850 5. Disconnect the idle purge vacuum line from fitting at throttle body This vacuum line is located on the front of throttle body next to the MAP sensor. Cap the fitting at throttle body after vacuum line has been removed. 6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under the instrument panel to the left of the steering column. 7. Start the engine. 8. Using the DRB scan tool, scroll through the menus as follows: select-System, select-Engine, select-Fuel and Ignition, select-Actuator Tests, select Engine rpm and select-Minimum Air Flow. 9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm. The idle rpm should be between 500 and 900 rpm. If the idle speed is outside of these specifications, replace the throttle body. 10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV valve. 13. Install air cleaner element housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions Air/Fuel Mixture: Technical Service Bulletins Fuel System/Engine Controls - Manual Revisions NUMBER: 26-02-99A GROUP: Miscellaneous DATE: February, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revision to the Diagnostic Trouble Codes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2855 45 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2856 46 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2857 47 Revision to the Throttle Position Sensor connector pin outs Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2858 152 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2859 156 Revision to the Fuel System Rich test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2860 316 Revisions to the Throttle Position sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2861 620 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2862 622 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair Accelerator Pedal: Service and Repair Fig 42 Accelerator Pedal Removal/Installation CAUTION: Be careful not to damage or kink the cable core wire (within the cable sheathing) while servicing accelerator pedal or cables. REMOVAL 1. From inside the vehicle, hold up accelerator pedal. - Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Fig. 42). - The plastic cable retainer snaps into pedal arm. 2. Remove 2 accelerator pedal/bracket nuts (Fig. 42) and remove pedal/bracket assembly from vehicle. Fig 43 Index Tab And Slot INSTALLATION 1. Position pedal/bracket assembly over the two dash panel mounting studs and install retaining nuts. 2. Tighten nuts to 8 N.m (75 in. lbs.) torque. 3. From inside the vehicle, hold up the accelerator pedal. - Install the throttle cable core wire and plastic cable retainer into the upper end of the pedal arm. - The plastic retainer is snapped into the pedal arm. - When installing the plastic retainer to the accelerator pedal arm, note the index tab on the pedal arm (Fig. 43). - Align the index slot (Fig. 43) on the plastic cable retainer to this index tab. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair Fig 52 Air Cleaner Components -- Typical REMOVAL 1. From engine compartment, remove plastic air intake tube at front of air cleaner housing. Tube snaps onto air cleaner housing. 2. Remove engine cover. 3. Pull crankcase breather/filter (straight up) from engine valve cover. 4. Remove wing nut and remove air cleaner assembly from throttle body. INSTALLATION 1. Position air cleaner housing to throttle body. 2. If housing-to-throttle body mounting stud is being installed, tighten to 10 N.m (90 in. lbs.) torque. 3. Tighten wingnut to 1.5 N.m (15 in. lbs.) torque. 4. Push crankcase breather/filter into valve cover. 5. Install plastic air intake tube to housing. 6. Install engine cover. AIR CLEANER ELEMENT Housing removal is not necessary for element (filter) replacement. REMOVAL 1. Remove engine cover. 2. Remove wingnut and remove cover from housing. 3. Remove air cleaner element from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Install housing cover to housing. 3. Install wingnut. 4. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Engine - High Driveability Index Fuels Fuel: Technical Service Bulletins Engine - High Driveability Index Fuels NO: 14-08-97 GROUP: Fuel DATE: Nov. 21, 1997 SUBJECT: Poor Driveability With High DI (Driveability Index) Fuel MODELS: 1996 - 1998 (AB) Ram Van/Wagon 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1996 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (PL) Neon 1997 (PR) Prowler 1996 - 1998 (SR) Viper Roadster/Coupe 1997 - 1998 (TJ) Wrangler 1996 - 1998 (XJ) Cherokee 1995 - 1998 (ZJ) Grand Cherokee SYMPTOM/CONDITION: Long cold start times, warm-up sags, hesitations, and driveway die outs. These symptoms are most noticeable and severe at moderate ambient temperatures between 4 - 27 degrees C (40 - 80 degrees F). DISCUSSION: Gasoline with a high Driveability Index (DI) can cause the above described symptoms. DI is a measure of the gasolines total volatility, or tendency to vaporize completely. A high DI number is less volatile than a low DI number. Most premium gasoline sold in the U.S. has a higher (worse) DI index than regular or mid-grade gasoline. Use of premium gasoline is NOT recommended for vehicles designed to run on 87 (R+M)/2 regular or 89 (R+M)/2 midgrade gasoline. High DI gasolines also cause higher emissions for the same reasons they cause driveability problems. For vehicles that require an octane rating of 91 (R+M)/2, premium is recommended, or possibly required. Using premium fuel with a higher than recommended octane rating is not recommended. Owners who experience fuel related cold start and warm up driveability problems should try a gasoline with the recommended octane rating or different brands of gasoline until they find one that provides good performance. The octane quality of gasoline is only a measure of its resistance to spark knock. The use of higher than recommended octane gasoline under normal operating conditions does NOT improve startability, idle quality, fuel economy, driveability, acceleration, engine durability, or emissions. In fact, most higher octane gasolines available in the U.S. have higher DI values than regular gasoline. Customers are most likely to experience poor driveability with premium gasoline than with regular. Some vehicles, such as Viper, Prowler, 5.9L Grand Cherokee, 2.0L Turbo Talon, and 2.0L DOHC Neon have been specifically designed to take advantage of higher octane. These vehicles may have higher compression ratios, and/or more aggressive spark calibrations which provide optimum performance with the specified higher octane. However, other vehicles which are not specifically designed and calibrated to take advantage of higher octane will not benefit from higher octane. Some vehicles may experience light spark knock in situations such as trailer towing or climbing steep sustained grades. Light knock or "ping" under these conditions is not harmful. However, if the customer is concerned about light knock under these circumstances, the use of 89 (R+M)/2 or even 91 (R+M)/2 premium gasoline may be temporarily warranted. If a vehicle is experiencing heavy spark knock on gasoline with its designed octane rating, this may be an indication of excessive combustion chamber deposits, or some other problem. Combustion chamber deposits can be removed with Mopar Combustion Chamber Conditioner p/n 04318001. Standard diagnostic procedures may help in identifying other potential causes of excessive knock. Some gasoline marketers may advertise that their premium gasoline contains extra detergent additives. Under provisions of the Clean Air Act, ALL gasoline sold in the U.S. must contain effective deposit control additives. Nevertheless, if fuel injector or intake valve deposits are suspected of Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Engine - High Driveability Index Fuels > Page 2873 contributing to poor performance, occasional use of Mopar Fuel Injector Clean Up p/n 04549613 is a much less expensive way to maintain engine cleanliness than regular use of premium gasoline. The charts (Figures 1 & 2) show the negative effects of high DI fuel as related to customer satisfaction. If fuel quality is suspected in causing a customers driveability concern, your zone technical office may be able to provide direction on procedures for fuel sample analysis. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation DESCRIPTION The loss of any fuel or vapor out of filler neck is prevented by the use of a pressure-vacuum fuel tank filler tube cap. OPERATION Relief valves inside the cap will release fuel tank pressure at predetermined pressures. Fuel tank vacuum will also be released at predetermined values. This cap must be replaced by a similar unit if replacement is necessary. This is in order for the system to remain effective. CAUTION: Remove fuel tank filler tube cap before servicing any fuel system component. This is done to help relieve tank pressure. If equipped with a California emissions package and a Leak Detection Pump (LDP), the secondary seal below the fill cap must be pressed (opened) to relieve fuel tank pressure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair NOTE: Use following procedure if fuel rail is or is not equipped with fuel pressure test port. 1. Remove fuel fill cap. 2. The fuel filler tube contains a spring-loaded flap (door) located below fuel fill cap. The flap is used as a secondary way of sealing fuel tank if fuel fill cap has not been properly tightened. It is part of EVAP monitor system when vehicle is equipped with a Leak Detection Pump (LDP). The vehicle may be equipped with flap installed into fuel filler tube even though vehicle is not equipped with LDP and EVAP monitor system. Place a nonmetallic object into fuel fill tube and press on flap to relieve any tank pressure. 3. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 7. Unplug connector from any injector. 8. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 9. Connect other end of jumper wire to positive side of battery. 10. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 11. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 12. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 13. Disconnect quick-connect fitting at fuel rail. 14. Return fuel pump relay to PDC. 15. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Injector Resistance ...................................................................................................................................................... 12 ohms ± 1.2 ohms at 20 ° C (68 ° F) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 2885 Fuel Injector: Pressure, Vacuum and Temperature Specifications Injector Fuel Pressure Normal operating fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). If pressure falls below 30 psi for five minutes. It must be determine if a fuel injector, fuel pump module check valve or fuel tube/line is leaking. Fuel Pressure Leak Down Test Fig 9 Connecting Adaptor Tool -- Typical Fig. 8 Installing Adapter Tool And Pressure Gauge NOTE: Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: Fuel pressure bleeding past a fuel injector(s). - Fuel pressure bleeding past the check valve in the fuel pump module. 1. Disconnect the fuel inlet line at fuel rail. - On some engines, air cleaner housing removal may be necessary before fuel line disconnection. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 2886 2. Connect the appropriate Fuel Line Pressure Test Adapter Tool (number 6539, 6631, 6541 or 6923) between the disconnected fuel line and fuel rail (Fig. 9) or (Fig. 10). 3. Connect the 0-414 kPa (0-60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. - The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 4. Start engine and bring to normal operating temperature. 5. Observe test gauge. Normal operating pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). 6. Shut engine off. 7. Pressure should not fall below 30 psi for five minutes. 8. If pressure falls below 30 psi, it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 9. Again, start engine and bring to normal operating temperature. 10. Shut engine off. 11. Testing for fuel injector or fuel rail leakage: - Clamp off the rubber hose portion of Adaptor Tool between the fuel rail and the test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a fuel injector or the fuel rail is leaking. 12. Testing for fuel pump check valve, filter/regulator check valve or fuel tube/line leakage: - Clamp off the rubber hose portion of Adaptor Tool between the vehicle fuel line and test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a leak may be found at a fuel tube/line. - If no leaks are found at fuel tubes or lines, one of the check valves in either the electric fuel pump or filter/ regulator may be leaking. NOTE: A quick loss of pressure usually indicates a defective check valve in the filter/regulator. A slow loss of pressure usually indicates a defective check valve in the electric fuel pump. The electric fuel pump is not serviced separately -- Replace the fuel pump module assembly. The filter/ regulator may be replaced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/installation for additional information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2887 Injector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2888 Injector #1 Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2889 Fuel Injector: Description and Operation Fuel Injector - Typical DESCRIPTION The fuel injectors are electrical solenoids. The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a pencil stream. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. OPERATION An individual fuel injector is used for each individual cylinder. The top (fuel entry) end of the injector is attached into an opening on the fuel rail. The nozzle outlet) ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector. The injectors are energized individually in a sequential order by the powertrain control module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector on and off. Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives. During start up, battery voltage is supplied to the injectors through the ASD relay. When the engine is operating, voltage is supplied by the charging system. The PCM determines injector pulse width based on various inputs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2890 Fuel Injector: Testing and Inspection Fig. 10 Fuel Injector Internal Components - Typical To test the injector only, disconnect the fuel injector wire harness connector from the injector. Place an ohmmeter across the injector terminals. Resistance reading should be approximately 12 ohms +/- 1.2 ohms at 20°C (68°F). CAUTION: Do not leave electrical current applied to the injector for longer than five seconds. Damage to injector coil or internal injector seals (Fig. 10) could result. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2891 Fuel Injector: Service and Repair WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE TURNED OFF). BEFORE SERVICING THE FUEL INJECTOR(S), THE FUEL SYSTEM PRESSURE MUST BE RELEASED. NOTE: To remove one or more fuel injectors, the fuel rail assembly must be removed from engine. REMOVAL 1. Remove engine cover. 2. Remove air cleaner assembly. 3. Remove fuel injector rail assembly. Fig. 33 Fuel Injector Mounting-Typical Fig. 34 Injector Retaining Clips-Typical Injector 4. Remove the clip(s) retaining the injector(s) to fuel rail. 5. Remove injector(s) from fuel rail. INSTALLATION 1. Apply a small amount of engine oil to each fuel injector 0-ring. This will help in fuel rail installation. 2. Install injector(s) and injector clip(s) to fuel rail. 3. Install fuel rail assembly. 4. Install air cleaner. 5. Start engine and check for leaks. 6. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation Fuel Line Coupler: Description and Operation Different types of quick-connect fittings are used to attach various fuel system components. These are: a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. CAUTION: The interior components (0-rings, spacers) of quick-connect fitting are not serviced separately, but new pull tabs are available for some types. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Plastic Retainer Type Fuel Line Coupler: Service and Repair Plastic Retainer Type Fig. 15 Plastic Retainer Ring Type Fitting This type of fitting can be identified by the use of a full-round plastic retainer ring usually black in color. CAUTION: The interior components (0-rings, spacers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. Refer to the fuel system pressure release procedure. DISCONNECTION/CONNECTION 1. Disconnect negative battery cable from the battery 2. Perform the fuel pressure release procedure. Refer to the Fuel Pressure Release Procedure. 3. Clean the fitting of any foreign material before disassembly 4. To release the fuel system component from the quick-connect fitting, firmly push the fitting towards the component being serviced while firmly pushing the plastic retainer ring into the fitting. With the plastic ring depressed, pull the fitting from the component. The plastic retainer ring must be pressed squarely into the fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on the shoulder of the plastic retainer ring to aid in disconnection. 5. After disconnection, the plastic retainer ring will remain with the quick-connect fitting connector body. 6. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. 7. Prior to connecting the quick-connect fitting to component being serviced, check condition of fitting and component. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. 8. Insert the quick-connect fitting into the component being serviced until a click is felt. 9. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 10. Connect negative battery cable to battery 11. Start engine and check for leaks. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Plastic Retainer Type > Page 2897 Fuel Line Coupler: Service and Repair Single TAB Type Fittings Fig. 11 Single-Tab Type Fitting This type of fitting is equipped with a single pull tab. The tab is removable. After the tab is removed, the quick-connect fitting can be separated from the fuel system component. CAUTION: The interior components (0-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new pull tabs are available. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. DISCONNECTION/CONNECTION 1. Disconnect negative battery cable from battery. 2. Perform the fuel pressure release procedure. 3. Clean the fitting of any foreign material before disassembly. Fig. 12 Disconnecting Single-Tab Type Fitting 4. Press the release tab on the side of fitting to release pull tab. CAUTION: If this release tab is not pressed prior to releasing the pull tab, the pull tab will be damaged. 5. While pressing the release tab on the side of the fitting, use a screwdriver to pry up the pull tab. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Plastic Retainer Type > Page 2898 Fig. 13 Removing Pull Tab 6. Raise the pull tab until it separates from the quick-connect fitting. Discard the old pull tab. 7. Disconnect the quick-connect fitting from the fuel system component being serviced. 8. Inspect the quick-connect fitting body and fuel system component for damage. Replace as necessary. 9. Prior to connecting the quick-connect fitting to component being serviced, check condition of fitting and component. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. 10. Insert the quick-connect fitting into the fuel tube or fuel system component until the built-on stop on the fuel tube or component rests against back of fitting. 11. Obtain a new pull tab. Push the new tab down until it locks into place in the quick-connect fitting. 12. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 13. Connect negative cable to battery. 14. Start engine and check for leaks. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Plastic Retainer Type > Page 2899 Fuel Line Coupler: Service and Repair Two TAB Type Fittings Fig. 14 Typical Two-Tab Type Quick-Connect Fitting Fuel Line Quick Connect Fitting Fuel Line Quick Connect Fitting This type of fitting is equipped with tabs located on both sides of the fitting. These tabs are supplied for disconnecting the quick-connect fitting from component being serviced. CAUTION: The interior components (0-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new plastic retainers are available. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. Refer to the fuel pressure release procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Plastic Retainer Type > Page 2900 DISCONNECTION/CONNECTION 1. Disconnect negative battery cable from the battery 2. Perform the fuel pressure release procedure. Refer to the Fuel Pressure Release Procedure. 3. Clean the fitting of any foreign material before disassembly 4. To disconnect the quick-connect fitting, squeeze the plastic retainer tabs against the sides of the quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. Pull the fitting from the fuel system component being serviced. The plastic retainer will remain on the component being serviced after fitting is disconnected. The 0-rings and spacer will remain in the quick- connect fitting connector body. 5. Inspect the quick-connect fitting body and component for damage. Replace as necessary. CAUTION: When the quick-connect fitting was disconnected, the plastic retainer will remain on the component being serviced. If this retainer must be removed, very carefully release the retainer from the component with two small screwdrivers. After removal, inspect the retainer for cracks or any damage. 6. Prior to connecting the quick-connect fitting to component being serviced, check condition of fitting and component. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. 7. Insert the quick-connect fitting to the component being serviced and into the plastic retainer. when a connection is made, a click will be heard. 8. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 9. Connect negative cable to battery 10. Start engine and check for leaks. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Plastic Retainer Type > Page 2901 Fuel Line Coupler: Service and Repair Latch Type Fitting (Fuel Rail-to-Fuel Line) Quick Connect Fitting At Fuel Rail A latch clip is used to secure the fuel line quick-connect fitting to the fuel rail. Special tools are not necessary to separate fuel line from fuel rail with this type of fitting. CAUTION: The interior components (0-rings, spacers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: THE FUEL SYSTEM MAY BE UNDER A CONSTANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, FUEL SYSTEM PRESSURE MUST BE RELEASED. DISCONNECTION/CONNECTION 1. Perform fuel pressure release procedure. 2. Disconnect negative battery cable from battery. 3. Clean fitting of any foreign material before disassembly. 4. Place rag or shop towel below fitting. 5. Pinch sides of latch and rotate up for removal. 6. Pull fuel line from fuel rail. 7. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line. 8. Prior to connecting fuel line to fuel rail, check condition of both fittings. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 9. Insert fuel line onto fuel rail. 10. Rotate latch clip (snaps into position). If latch clip will not fit, this indicates fuel line is not properly installed to fuel rail. Recheck fuel line connection. 11. Verify a locked condition by firmly pulling on fuel line and fitting (15-30 lbs.). 12. Connect negative battery cable to battery 13. Start engine and check for leaks. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Fuel Pressure Regulator: Locations Fig 1 Top View Of Fuel Pump Module Fig 3 Side View -- Filter/Pressure Regulator Fig 2 Fuel Pump Module Components -- Typical A combination fuel filter and fuel pressure regulator is pressed into a rubber grommet located on the top of the fuel pump module. A separate frame mounted fuel filter is not used. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2905 Fuel Pressure Regulator: Description and Operation Fig 3 Side View -- Filter/Pressure Regulator DESCRIPTION A combination fuel filter and fuel pressure regulator is used on all engines. It is located on the top of the fuel pump module. A separate frame mounted fuel filter is not used with any engine. Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. OPERATION Fuel Pressure Regulator Operation: The pressure regulator is a mechanical device that is not controlled by engine vacuum or the powertrain control module (PCM). The regulator is calibrated to maintain fuel system operating pressure of approximately 339 kPa ± 34 kPa (49.2 psi ± 5 psi) at the fuel injectors. It contains a diaphragm, calibrated springs and a fuel return valve. The internal fuel filter is also part of the assembly Fuel is supplied to the filter/regulator by the electric fuel pump through an opening tube at the bottom of filter/regulator. The regulator acts as a check valve to maintain some fuel pressure when the engine is not operating. This will help to start the engine. A second check valve is located at the outlet end of the electric fuel pump. If fuel pressure at the pressure regulator exceeds approximately 49.2 psi, an internal diaphragm opens and excess fuel pressure is routed back into the tank through the bottom of pressure regulator. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2906 Fuel Pressure Regulator: Service and Repair Fig 1 Top View Of Fuel Pump Module Fig 3 Side View -- Filter/Pressure Regulator Fig 2 Fuel Pump Module Components -- Typical NOTE: The fuel filter/fuel pressure regulator is located on top of fuel pump module. NOTE: Two different types of filter/regulators are used. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2907 - If a rubber grommet is located between the bottom of filter/regulator and top of fuel pump module, it can be serviced separately. Refer to the following procedure. - If this grommet is not used, it cannot be serviced separately The Fuel Pump Module assembly must be replaced. Refer to Fuel Pump Module Removal/Installation for procedures. WARNING: The fuel system is under a constant pressure, even with engine off. Before servicing the fuel filter/fuel pressure regulator, the fuel system pressure must be released. TIP: Fuel pump module removal is not necessary. REMOVAL 1. Drain fuel tank and remove tank. - Refer to Fuel Tank Removal/Installation. Fig 22 Filter/Regulator Location 2. The fuel filter/regulator is pressed into a rubber grommet. - Remove by twisting and pulling straight up (Fig. 23). CAUTION: Do not pull the filter/regulator more than three inches from the fuel pump module. Damage to the coiled fuel tube (line) may result. Fig 24 Plastic Tube And Snap Ring -- Typical 3. Remove the snap ring retaining the convoluted tube (cover) to the filter/regulator (Fig. 24). Slide the plastic tube down the fuel tube to clear the fuel tube clamp. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2908 Fig 25 Fuel Tube And Clamp -- Typical 4. Gently cut the old fuel tube (line) clamp (Fig. 25) taking care not to damage the plastic fuel tube. Remove and discard the old fuel tube clamp. 5. Remove the plastic fuel tube from the filter/regulator gently pulling downward. Remove filter/regulator from fuel pump module. Fig 26 Tightening Fuel Tube Clamp -- Typical INSTALLATION 1. Install a new clamp over the plastic fuel tube. 2. Install filter/regulator to fuel tube. - Rotate the filter/regulator in the fuel tube (line) (Fig. 26) until it is pointed to the drivers side of vehicle (Fig. 22). 3. Tighten line clamp to fuel line using special Hose Clamp Pliers number C-4124 or equivalent (Fig. 26). - Do not use conventional side cutters to tighten this type of clamp. 4. Slide the convoluted plastic tube (cover) up to the bottom of filter/regulator and install snap ring (Fig. 24). 5. Press the filter/regulator (by hand) into the rubber grommet. - The assembly should be pointed to the drivers side of vehicle (Fig. 22 ). 6. Install fuel tank. - Refer to Fuel Tank Removal/Installation. 7. Check for fuel leaks. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage NO: 14-03-98 GROUP: Fuel DATE: May 1, 1998 SUBJECT: Fuel Pressure Gauge Adapter Usage MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) DISCUSSION: Currently, four different fuel pressure adapters are required, depending on application, to attach a fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications Fuel Pressure: Pressure, Vacuum and Temperature Specifications Fuel Pressure Engine at curb idle ............................................................................................................................... ........................................ 339 ± 34 kPa (49.2 ± 5 psi) Pressure Leakdown (fuel pump not engaged) ................................................................................................................. Not fall below 30 psi for 5 minutes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2916 Fuel Pressure: Capacity Specifications NOTE: Before performing this test, verify fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. - Refer to the Fuel Pressure Release Procedure. 2. Disconnect the fuel supply line at fuel rail. - Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. - Insert other end of Adaptor Tool hose into a graduated container. 4. Remove the fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. - Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. - Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test Fig 9 Connecting Adaptor Tool -- Typical Fig. 8 Installing Adapter Tool And Pressure Gauge NOTE: Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: Fuel pressure bleeding past a fuel injector(s). - Fuel pressure bleeding past the check valve in the fuel pump module. 1. Disconnect the fuel inlet line at fuel rail. - On some engines, air cleaner housing removal may be necessary before fuel line disconnection. 2. Connect the appropriate Fuel Line Pressure Test Adapter Tool (number 6539, 6631, 6541 or 6923) between the disconnected fuel line and fuel rail (Fig. 9) or (Fig. 10). 3. Connect the 0-414 kPa (0-60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. - The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 4. Start engine and bring to normal operating temperature. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2919 5. Observe test gauge. Normal operating pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). 6. Shut engine off. 7. Pressure should not fall below 30 psi for five minutes. 8. If pressure falls below 30 psi, it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 9. Again, start engine and bring to normal operating temperature. 10. Shut engine off. 11. Testing for fuel injector or fuel rail leakage: - Clamp off the rubber hose portion of Adaptor Tool between the fuel rail and the test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a fuel injector or the fuel rail is leaking. 12. Testing for fuel pump check valve, filter/regulator check valve or fuel tube/line leakage: - Clamp off the rubber hose portion of Adaptor Tool between the vehicle fuel line and test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a leak may be found at a fuel tube/line. - If no leaks are found at fuel tubes or lines, one of the check valves in either the electric fuel pump or filter/ regulator may be leaking. NOTE: A quick loss of pressure usually indicates a defective check valve in the filter/regulator. A slow loss of pressure usually indicates a defective check valve in the electric fuel pump. The electric fuel pump is not serviced separately -- Replace the fuel pump module assembly. The filter/ regulator may be replaced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/installation for additional information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2920 Fuel Pressure: Testing and Inspection Fuel Pressure Test Fuel Pressure Test Gauge NOTE: Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test, fuel pump amperage test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow hack into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. WARNING: The fuel system is under constant fuel pressure even with the engine off. Before disconnecting fuel line at fuel rail, this pressure must be released. Refer to the fuel system pressure release procedure. NOTE: To perform this test you will need to remove the engine cover. 1. Remove the protective cap at the fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port pressure fitting on the fuel rail. 2. Start and warm the engine and note pressure gauge reading. Fuel pressure should be 3.39 kPa +/- 34 kPa (49.2 psi +/- 5 psi) at idle. 3. If engine runs but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, replace fuel pump module assembly. Refer to Fuel Pump Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel filter/fuel pressure regulator. Certain filter/regulators may be serviced separately and some require the replacement of the fuel pump module assembly Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2921 Fuel Pressure: Testing and Inspection Fuel Pump Amperage Test This amperage (current draw) test is to be done in conjunction with the Fuel Pump Pressure Test, Fuel Pump Capacity Test and Fuel Pressure Leak Down Test. Before performing the amperage test, be sure the temperature of the fuel tank is above 50° F (10° C). The DRB Scan Tool along with the DRB Low Current Shunt (LCS) adapter and its test leads will be used to check fuel pump amperage specifications. Low Current Shunt Adapter 1. Obtain LCS adapter. 2. Plug cable from LCS adapter into DRB scan tool at SET 1 receptacle. 3. Plug DRB into vehicle 16-way connector (data link connector). 4. Connect (-) and (+) test cable leads into LCS adapter receptacles. Use 10 amp (10A +) receptacle and common (-) receptacles. 5. Gain access to MAIN MENU on DRB screen. 6. Press DVOM button on DRB. 7. Using left/right arrow keys, highlight CHANNEL 1 function on DRB screen. 8. Press ENTER three times. 9. Using up/down arrow keys, highlight RANGE on DRB screen (screen will default to 2 amp scale). 10. Press ENTER to change 2 amp scale to 10 amp scale. This step must be done to prevent damage to DRB scan tool or LCS adapter (blown fuse). 11. Remove cover from Power Distribution Center (PDC). 12. Remove fuel pump relay from PDC. Refer to label on PDC cover for relay location. WARNING: BEFORE PROCEEDING TO NEXT STEP, NOTE THE FUEL PUMP WILL BE ACTIVATED AND SYSTEM PRESSURE WILL BE PRESENT. THIS WILL OCCUR AFTER CONNECTING TEST LEADS FROM LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES. THE FUEL PUMP WILL OPERATE EVEN WITH IGNITION KEY IN OFF POSITION. BEFORE ATTACHING TEST LEADS, BE SURE ALL FUEL LINES AND FUEL SYSTEM COMPONENTS ARE CONNECTED. CAUTION: To prevent possible damage to the vehicle electrical system and LCS adapter, the test leads must be connected into relay cavities exactly as shown in following steps. Depending upon vehicle model, year or engine configuration, three different types of relays may be used: Type-1, type-2 and type-3. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2922 Starter Relay 13 If equipped with type-1 relay, attach test leads from LCS adapter into PDC relay cavities number 30 and 87. For location of these cavities, refer to numbers stamped to bottom of relay. Type-2 Relay 14. If equipped with type-2 relay, attach test leads from LCS adapter into PDC relay cavities number 30 and 87. For location of these cavities, refer to numbers stamped to bottom of relay. Type-3 Relay 15. If equipped with type-3 relay, attach test leads from LCS adapter into PDC relay cavities number 3 and 5. For location of these cavities, refer to numbers stamped to bottom of relay. 16. When LCS adapter test leads are attached into relay cavities, fuel pump will be activated. Determine fuel pump amperage on DRB screen. Amperage should be below 10.0 amps. If amperage is below 10.0 amps, and specifications for the Fuel Pump Pressure, Fuel Pump Capacity and Fuel Pressure Leak Down tests were met, the fuel pump module is OK. 17. If amperage is more than 10.0 amps, replace fuel pump module assembly The electric fuel pump is not serviced separately. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2923 18. Disconnect test leads from relay cavities immediately after testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2924 Fuel Pressure: Testing and Inspection Fuel Pump Capacity Test NOTE: Before performing this test, verify fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. - Refer to the Fuel Pressure Release Procedure. 2. Disconnect the fuel supply line at fuel rail. - Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. - Insert other end of Adaptor Tool hose into a graduated container. 4. Remove the fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. - Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. - Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Fuel Pump Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2928 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2929 Fuel Pump Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2930 Fuel Pump Relay: Service and Repair Fig 2 Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2931 Power Distribution Center -- Under The Hood, Near The Brake Master Cylinder The fuel pump and automatic shutdown (ASD) relays are located in the Power Distribution Center (PDC). The PDC is located in the engine compartment in front of the brake master cylinder. Refer to label on PDC cover for relay location. Check the terminals in the PDC relay connector for corrosion or damage before installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications Fuel Rail: Specifications Mounting Bolts 23 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 2935 Fuel Rail: Description and Operation Fig. 6 Fuel Rail - Typical The fuel rail supplies the necessary fuel to each individual fuel injector and is mounted to the lower half of the two-piece intake manifold. The metal, one-piece fuel rail is not repairable. The fuel pressure regulator is no longer mounted to the fuel rail on any engine. It is now located on the fuel tank mounted fuel pump module. The fuel rail is not repairable. CAUTION: The left and right sections of the fuel rail are connected with a flexible connecting hose. Do not attempt to separate the rail halves at this connecting hose. Due to the design of this connecting hose, it does not use any clamps. Never attempt to install a clamping device of any kind to the hose. When removing the fuel rail assembly for any reason, be careful not to bend or kink the connecting hose. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 2936 Fuel Rail: Service and Repair WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE TURNED OFF). BEFORE SERVICING THE FUEL RAIL ASSEMBLY, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate the rail halves at the connecting hose. Due to the design of this connecting hose, it does not use any clamps. Never attempt to install a clamping device of any kind to the hose. When removing the fuel rail assembly for any reason, be careful not to bend or kink the connecting hose. Fuel Rail Assembly REMOVAL 1. Remove engine cover. 2. Remove negative battery cable at battery. 3. Remove air cleaner. 4. Perform the fuel pressure release procedure. 5. Remove throttle body from intake manifold. Fig. 31 A/C Compressor Support Bracket-Typical 6. If equipped with air conditioning, remove the A-shaped A/C compressor-to-intake manifold support bracket (three bolts). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 2937 Fig. 5 Fuel Injectors-5.2L Engines-Typical 7. Disconnect electrical connectors at all fuel injectors. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. 8. Disconnect fuel tube (line) at side of fuel rail. 9. Remove the remaining fuel rail mounting bolts. 10. Clean dirt/debris from each fuel injector at intake manifold. 11. Gently rock and pull the left fuel rail until the fuel injectors just start to clear the intake manifold. Gently rock and pull the right fuel rail until the fuel injectors just start to clear the intake manifold. Repeat this procedure (left/right) until all fuel injectors have cleared the intake manifold. 12. Remove fuel rail (with injectors attached) from engine. Fig. 33 Fuel Injector Mounting-Typical Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 2938 Fig. 34 Injector Retaining Clips-Typical Injector 14. Remove the clip(s) retaining the injector(s) to fuel rail. INSTALLATION 1. Apply a small amount of engine oil to each fuel injector 0-ring. This will help in fuel rail installation. 2. Install injector(s) and injector clip(s) to fuel rail. 3. Position the fuel rail/fuel injector assembly to the injector openings on the intake manifold. 4. Guide each injector into the intake manifold. Be careful not to tear the injector o-ring. 5. Push the right fuel rail down until fuel injectors have bottomed on injector shoulder. Push the left fuel rail down until fuel injectors have bottomed on injector shoulder. 6. Install fuel rail mounting bolts. 7. Connect electrical connector to intake manifold air temperature sensor. 8. Connect wiring to all fuel injectors. The injector wiring harness is numerically tagged. 9. Install the A/C support bracket (if equipped). 10. Install throttle body to intake manifold. 11. Install fuel tube (line) at side of fuel rail. 12. Install air cleaner. 13. Connect battery cable to battery. 14. Start engine and check for leaks. 15. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions Fuel Gauge Sender: Technical Service Bulletins Engine Controls/Fuel System - Service Manual Revisions NUMBER: 26-12-97H GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L, 3.9L, 5.2L, 8.0L Powertrain Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the "No Cam Signal at PCM" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page 2944 29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page 2945 56 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page 2946 58 Revision to the "Fuel Level Sending Unit" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page 2947 412 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 2948 Fuel Gauge Sender: Description and Operation DESCRIPTION The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a vanable resistor (track). The resistor track is used to send electrical signals to the Powertrain Control Module (PCM) for fuel gauge operation and for OBD II emission requirements. OPERATION For fuel gauge operation: As fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This increases the sending unit resistance causing the fuel gauge to read empty. After this fuel level signal is sent to the PCM, the PCM will transmit the data across the CCD bus circuits to the instrument panel. Here it is translated into the appropriate fuel gauge level reading. For OBD II emission monitor requirements: A voltage signal is sent from the resistor track on the sending unit to the PCM to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 2949 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. To test the gauge sending unit only, it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal Installation for procedures. Measure the resistance across the sending unit terminals. With float in up position, resistance should be 20 ohms ± 6 ohms. - With float in down position, resistance should be 220 ± 6 ohms. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 2950 Fuel Gauge Sender: Service and Repair Fig 30 Fuel Gauge Sending Unit Location The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located on top of fuel tank. REMOVAL 1. Remove fuel tank. 2. Remove fuel pump module. 3. Carefully separate the lower section of pump module from upper section by releasing three module lock tabs. Take care not to stretch plastic fuel line within module. 4. Unplug 6-way electrical connector. 5. Disconnect 2 sending unit wires at 6-way connector. Note location of wires within 6-way connector. Fig 31 Fuel Gauge Sending Lock Tab/Tracks 6. The sending unit is retained to pump module with a small lock tab and notch. Carefully pry up on lock tab to release from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 6-way connector. 4. Connect 6-way electrical connector to module. 5. Carefully connect lower section of pump module to upper section (3 tabs lock upper section to lower section). 6. Install fuel pump module. 7. Install fuel tank. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications Fuel Tank Unit: Specifications Fuel Pump Module Fuel Pump Module Locknut 40 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 2954 Fuel Tank Unit: Description and Operation Fuel Pump Module Fig 2 Fuel Pump Module Components -- Typical The fuel pump module on all gas powered engines is installed in the top of the fuel tank. The fuel pump module contains: - A combination fuel filter/fuel pressure regulator - Electric fuel pump - Fuel pump reservoir - A separate in-tank fuel filter - Fuel gauge sending unit - Fuel supply line connection at filter/regulator - A plastic threaded locknut to retain pump module to fuel tank - A gasket between tank flange and module The fuel gauge sending unit (fuel level sensor), and pick-up filter (at bottom of module) may be serviced separately. If the electrical fuel pump requires service, the entire fuel pump module must be replaced. The fuel filter/fuel pressure regulator may be serviced separately. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 2955 Fuel Tank Unit: Service and Repair Fuel Pump Module Fig 28 Locknut Removal/Installation -- Typical WARNING: The fuel system is under constant pressure, even when the engine is OFF. Always release fuel pressure before servicing any fuel system component. CAUTION: Whenever the fuel pump module is serviced, the locknut and gasket must be replaced. REMOVAL 1. Drain and remove fuel tank. 2. Thoroughly wash and clean area around pump module to prevent contaminants from entering tank. 3. The fuel pump module locknut is threaded onto fuel tank. - Install Special Tool 6856 to fuel pump module locknut and remove locknut (Fig. 28). - The fuel pump module will spring up when locknut is removed. 4. Remove module from fuel tank. CAUTION: Whenever the fuel pump module is serviced, the locknut and gasket must be replaced. INSTALLATION 1. Using a new gasket position fuel pump module into opening in fuel tank. 2. Rotate module assembly and align Index Arrow until pointed to rear of vehicle. 3. Position new locknut over top of fuel pump module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 2956 4. Install Special Tool 6856 to locknut. 5. Tighten locknut to 24-44 N.m (18-32 ft. lbs.) torque. 6. Install fuel tank. Fig 29 Fuel Pump Inlet Filter FUEL PUMP INLET FILTER The fuel pump inlet filter (strainer) is located on the bottom of fuel pump module (Fig. 29). The fuel pump module is located on top of fuel tank. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Remove filter by carefully prying 2 lock tabs at bottom of module with 2 screwdrivers. Filter is snapped to module. 4. Clean bottom of pump module. INSTALLATION 1. Snap new filter to bottom of module. 2. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications IAC Motor IAC Motor Mounting Bolts 7 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2960 Idle Speed/Throttle Actuator - Electronic: Locations Map Sensor,idle Air Control Motor,TP Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2961 Idle Air Control Motor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2962 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection To perform a complete test of the idle air control motor and circuits see Computers and Control Systems /System Diagnosis/Procedures/Diagnostic Charts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2963 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL 1. Remove air cleaner assembly. 2. Disconnect electrical connector from Idle Air Control (IAC) motor. Fig. 84 Mounting Bolts (Screws) - IAC 3. Remove two mounting bolts (screws). 4. Remove IAC motor from throttle body INSTALLATION 1. Install IAC motor to throttle body 2. Install and tighten two mounting bolts (screws) to 7 N.m (60 in. lbs.) torque. 3. Install electrical connector. 4. Install air cleaner assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Auto Shutdown Relay Connector, Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2967 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2968 Auto Shutdown Relay Connector, Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2969 Automatic Shut Down (ASD) Relay: Description and Operation SYSTEM OPERATION As one of its functions, the (ASD) relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2970 Automatic Shut Down (ASD) Relay: Testing and Inspection Fig. 24 Asd And Fuel Pump Relay Terminals The relay terminal numbers can be found on the bottom of the relay: - Terminal number 30 is connected to battery voltage and can be switched or B+ (hot) at all times. - The center terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the component being operated. - Terminal number 86 is connected to a switched (+) power source. - Terminal number 85 is grounded by the Powertrain Control Module (PCM). TESTING 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. - Resistance value (ohms) should be 75 +/- 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. - Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. - Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). - Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. - Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. - Continuity should now be present between terminals number 87 and 30. - Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 volt power source. If continuity or resistance tests did not pass, replace relay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2971 Automatic Shut Down (ASD) Relay: Service and Repair Fig 2 Power Distribution Center The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC coven 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. - Also check the heights of relay terminal pins at PDC. - Pin height should be same for all pins. - Repair as necessary before installing relay. 2. Push the relay into the connector. 3. Install the relay cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Fuel Pump Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2976 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2977 Fuel Pump Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2978 Fuel Pump Relay: Service and Repair Fig 2 Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2979 Power Distribution Center -- Under The Hood, Near The Brake Master Cylinder The fuel pump and automatic shutdown (ASD) relays are located in the Power Distribution Center (PDC). The PDC is located in the engine compartment in front of the brake master cylinder. Refer to label on PDC cover for relay location. Check the terminals in the PDC relay connector for corrosion or damage before installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Auto Shutdown Relay Connector, Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2983 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2984 Auto Shutdown Relay Connector, Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2985 Automatic Shut Down (ASD) Relay: Description and Operation SYSTEM OPERATION As one of its functions, the (ASD) relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2986 Automatic Shut Down (ASD) Relay: Testing and Inspection Fig. 24 Asd And Fuel Pump Relay Terminals The relay terminal numbers can be found on the bottom of the relay: - Terminal number 30 is connected to battery voltage and can be switched or B+ (hot) at all times. - The center terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the component being operated. - Terminal number 86 is connected to a switched (+) power source. - Terminal number 85 is grounded by the Powertrain Control Module (PCM). TESTING 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. - Resistance value (ohms) should be 75 +/- 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. - Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. - Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). - Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. - Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. - Continuity should now be present between terminals number 87 and 30. - Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 volt power source. If continuity or resistance tests did not pass, replace relay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2987 Automatic Shut Down (ASD) Relay: Service and Repair Fig 2 Power Distribution Center The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC coven 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. - Also check the heights of relay terminal pins at PDC. - Pin height should be same for all pins. - Repair as necessary before installing relay. 2. Push the relay into the connector. 3. Install the relay cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Description and Operation Rollover Valve: Description and Operation Fuel Pump Module DESCRIPTION The fuel tank is equipped with 2 interconnected rollover valves. The valves are located on the top of the fuel tank. These valves will prevent fuel flow through the fuel tank vent (EVAP) hoses in the event of an accidental vehicle rollover. OPERATION The EVAP canister draws fuel vapors from the fuel tank through these valves. The valves are not serviced separately if replacement is necessary, the fuel tank must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Description and Operation > Page 2991 Rollover Valve: Service and Repair The rollover valves(s) are/is molded into the fuel tank and are not serviced separately If replacement is necessary the fuel tank must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions Throttle Position Sensor: Technical Service Bulletins Fuel System/Engine Controls - Manual Revisions NUMBER: 26-02-99A GROUP: Miscellaneous DATE: February, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revision to the Diagnostic Trouble Codes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2997 45 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2998 46 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2999 47 Revision to the Throttle Position Sensor connector pin outs Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 3000 152 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 3001 156 Revision to the Fuel System Rich test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 3002 316 Revisions to the Throttle Position sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 3003 620 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 3004 622 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3005 Throttle Position Sensor: Specifications Mounting Screws 7 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3006 Throttle Position Sensor: Locations Map Sensor Throttle Position Sensor, Idle Air Control Motor, Throttle Position Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3007 Throttle Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3008 Throttle Position Sensor: Testing and Inspection The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). - At idle, TPS output voltage should should be greater than 0.350 millivolts and less than 900 millivolts. - At wide open throttle, TPS output voltage must be less than 4.5 volts. - The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. NOTE: For additional testing information and circuit diagnosis see Computers and Control Systems/System Diagnosis/Procedures/Diagnostic Charts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3009 Throttle Position Sensor: Service and Repair Fig 80 TPS Mounting Bolts REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body Fig. 81 Installation INSTALLATION The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Mounting Bolts 23 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3013 Throttle Body: Description and Operation DESCRIPTION The throttle position sensor (TPS), idle air control (IAC) motor and manifold absolute pressure sensor (MAP) are attached to the throttle body The accelerator pedal cable, speed control cable and transmission control cable (when equipped) are connected to the throttle arm. A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the Powertrain Control Module (PCM). OPERATION Fig. 30 Throttle Body Fig. 31 Air Control Passage Filtered air from the air cleaner enters the intake manifold through the throttle body. Fuel does not enter the intake manifold through the throttle body. Fuel is sprayed into the manifold by the fuel injectors. The throttle body is mounted on the intake manifold. It contains an air control passage controlled by an idle air control (IAC) motor. The air control passage is used to supply air for idle conditions. A throttle valve (plate) is used to supply air for above idle conditions. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3014 Throttle Body: Testing and Inspection The following test procedure has been developed to check throttle body calibrations for correct idle conditions. The procedure should be used to diagnose the throttle body for conditions that may cause idle problems. This procedure should be used only after normal diagnostic procedures have failed to produce results that indicate a throttle body related problem. Be sure to check for proper operation of the idle air control motor before performing this test. Fig. 73 Fixed Orifice Tool A special fixed orifice tool (number 6714) must be used for the following test. 1. Start the engine and bring to operating temperature. Be sure all accessories are off before performing this test. 2. Shut off the engine and remove the air cleaner element housing. Fig. 74 Install Orifice Tool 3. Disconnect the vacuum line at the PCV valve. 4. Install the 0.185 inch orifice tool (number 6714) into the disconnected vacuum line in place of the PCV valve. Fig. 75 Idle Purge Line Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3015 5. Disconnect the idle purge vacuum line from fitting at throttle body This vacuum line is located on the front of throttle body next to the MAP sensor. Cap the fitting at throttle body after vacuum line has been removed. 6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under the instrument panel to the left of the steering column. 7. Start the engine. 8. Using the DRB scan tool, scroll through the menus as follows: select-System, select-Engine, select-Fuel and Ignition, select-Actuator Tests, select Engine rpm and select-Minimum Air Flow. 9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm. The idle rpm should be between 500 and 900 rpm. If the idle speed is outside of these specifications, replace the throttle body. 10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV valve. 13. Install air cleaner element housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3016 Throttle Body: Service and Repair A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the Powertrain Control Module (PCM). REMOVAL 1. Remove the air cleaner. Fig. 40 Sensor And IAC Location - Typical 2. Disconnect throttle body electrical connectors at Manifold Absolute Pressure (MAP) sensor, Idle Air Control (IAC) motor and Throttle Position Sensor (TPS). 3. Remove vacuum line at throttle body. 4. Remove all control cables from throttle body (lever) arm. Refer to Accelerator Cable/Service and Repair. Fig. 30 Throttle Body 5. Remove four throttle body mounting bolts. 6. Remove throttle body from intake manifold. 7. Discard old throttle body-to-intake manifold gasket. INSTALLATION 1. Clean the mating surfaces of the throttle body and the intake manifold. 2. Install new throttle body-to-intake manifold gasket. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3017 3. Install throttle body to intake manifold. 4. Install four mounting bolts. Tighten bolts to 23 N.m (200 in. lbs.) torque. 5. Install control cables. 6. Install vacuum line to throttle body 7. Install electrical connectors. 8. Install air cleaner. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair Throttle Cable/Linkage: Service and Repair Fig 42 Accelerator Pedal Removal/Installation CAUTION: Be careful not to damage or kink the cable core wire (within the cable sheathing) while servicing accelerator pedal or cables. REMOVAL 1. From inside the vehicle, hold up accelerator pedal. - Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Fig. 42). - Plastic cable retainer snaps into pedal arm. 2. Remove the cable core wire at the pedal arm. 3. From inside the vehicle, pinch both sides of the cable housing retainer at the dash panel (Fig. 42). - Remove cable housing from dash panel and pull into the engine compartment. 4. Remove engine cover. 5. Remove the air cleaner housing. 6. Operate the throttle body lever (by hand) to the full open throttle position. Slip the cable end rearward from pin on throttle lever (Fig. 44). Fig 45 Cable Release Tab -- Typical 7. Remove cable housing at throttle body mounting bracket by pressing forward on release tab with a small screwdriver (Fig. 45). - To prevent cable housing breakage, press on the tab only enough to release the cable from the bracket. - Lift the cable housing straight up from bracket while pressing on release tab. - Remove cable housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 3021 8. Remove cable from vehicle. Fig 44 Throttle Cable At Throttle Body -- Typical INSTALLATION 1. Snap the cable end onto lever pin (Fig. 44). On models with V-8 engines, be sure cable is routed under plastic cam (Fig. 44). 2. Connect cable to throttle body mounting bracket (push down and lock). 3. Install the remaining cable housing end into the dash panel opening (snaps into position). Fig 43 Index Tab And Slot 4. Install the ball end of the cable wire through the hole in the pedal arm. - Install the plastic cable retainer. - The plastic retainer is snapped into the pedal arm. - When installing the retainer to the accelerator pedal arm, note the index tab on the pedal arm (Fig. 43). - Align the index slot (Fig. 43) on the plastic retainer to this index tab. 5. Operate and test the throttle before starting engine. 6. Install air cleaner housing. 7. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions Throttle Position Sensor: Technical Service Bulletins Fuel System/Engine Controls - Manual Revisions NUMBER: 26-02-99A GROUP: Miscellaneous DATE: February, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revision to the Diagnostic Trouble Codes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 3026 45 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 3027 46 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 3028 47 Revision to the Throttle Position Sensor connector pin outs Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 3029 152 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 3030 156 Revision to the Fuel System Rich test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 3031 316 Revisions to the Throttle Position sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 3032 620 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 3033 622 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3034 Throttle Position Sensor: Specifications Mounting Screws 7 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3035 Throttle Position Sensor: Locations Map Sensor Throttle Position Sensor, Idle Air Control Motor, Throttle Position Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3036 Throttle Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3037 Throttle Position Sensor: Testing and Inspection The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). - At idle, TPS output voltage should should be greater than 0.350 millivolts and less than 900 millivolts. - At wide open throttle, TPS output voltage must be less than 4.5 volts. - The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. NOTE: For additional testing information and circuit diagnosis see Computers and Control Systems/System Diagnosis/Procedures/Diagnostic Charts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3038 Throttle Position Sensor: Service and Repair Fig 80 TPS Mounting Bolts REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body Fig. 81 Installation INSTALLATION The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3050 Camshaft Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3051 Camshaft Position Sensor: Description and Operation SYSTEM OPERATION The camshaft position sensor is located in the distributor on all engines. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3052 Camshaft Position Sensor: Testing and Inspection Camshaft Position Sensor - Typical The camshaft position sensor is located in the distributor on all engines. To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostics Procedures service. To test the sensor only, refer to the following: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Remove engine cover. 2. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. For wire identification. 3. Connect the negative (-) voltmeter lead into the ground wire. For wire identification. 4. Set the voltmeter to the 15 Volt DC scale. 5. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 6. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 7. If voltage is not present, check the voltmeter leads for a good connection. 8. If voltage is still not present, check for voltage at the supply wire. For wire identification. 9. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 10. If voltage is still not present, perform vehicle test using the DRB scan tool. 11. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM. If continuity is not present, repair the harness as necessary c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 12. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3053 Camshaft Position Sensor: Service and Repair The camshaft position sensor is located in the distributor. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove engine cover. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. Crankshaft Position Sensor 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Mounting Bolts 8 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3057 Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3058 Crankshaft Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3059 Crankshaft Position Sensor: Description and Operation SYSTEM OPERATION Sensor Operation Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. On this engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3060 Crankshaft Position Sensor: Testing and Inspection To perform a complete test of this sensor and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3061 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor - Typical The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. 1. Remove engine cover. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 N.m (70 in.lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Cap Inspection-External-Typical Cap Inspection-Internal-Typical Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. The machined surface of a terminal end (faces toward rotor) will indicate some evidence of erosion from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Rotor Inspection-Typical Visually inspect the rotor for cracks, evidence of corrosion or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 3077 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 3078 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 3079 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 3080 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 3081 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 3082 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 3088 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 3089 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 3090 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 3091 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 3092 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 3093 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 3094 Ignition Cable: Specifications MINIMUM = MAXIMUM 250 Ohms Per Inch = 1000 Ohms Per Inch 3000 Ohms Per Foot = 12,000 Ohms Per Foot Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 3095 Ignition Cable: Description and Operation SYSTEM OPERATION Spark plug cables are sometimes referred to as secondary ignition wires. These cables transfer electrical current from the ignition coil(8) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 3096 Ignition Cable: Testing and Inspection Heat Shields Check the spark plug cable connections for good contact at the coil(s), distributor cap towers, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, distributor and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean high voltage ignition cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Spark plug cable heat shields are pressed into the cylinder head to surround each spark plug cable boot and spark plug . These shields protect the spark plug boots from damage (due to intense engine heat generated by the exhaust manifolds) and should not be removed. After the spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat shield. Testing When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment manufacturer. If an oscilloscope is not available, spark plug cables may be tested as follows: CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. With the engine running, remove spark plug cable from spark plug (one at a time) and hold next to a good engine ground. If the cable and spark plug are in good condition, the engine rpm should drop and the engine will run poorly If engine rpm does not drop, the cable and/or spark plug may not be operating properly and should be replaced. Also check engine cylinder compression. With the engine not running, connect one end of a test probe to a good ground. Start the engine and run the other end of the test probe along the entire length of all spark plug cables. If cables are cracked or punctured, there will be a noticeable spark jump from the damaged area to the test probe. The cable running from the ignition coil to the distributor cap can be checked in the same manner. Cracked, damaged or faulty cables should be replaced with resistance type cable. This can be identified by the words ELECTRONIC SUPPRESSION printed on the cable jacket. Use an ohmmeter to test for open circuits, excessive resistance or loose terminals. If equipped, remove the distributor cap from the distributor. Do not remove cables from cap. Remove cable from spark plug. Connect ohmmeter to spark plug terminal end of cable and to corresponding electrode in distributor cap. Resistance should be 250 to 1000 Ohms per inch of cable. If not, remove cable from distributor cap tower and connect ohmmeter to the terminal ends of cable. If resistance is not within specifications as found in the SPARK PLUG CABLE RESISTANCE chart, replace the cable. Test all spark plug cables in this manner. Spark Plug Cable Resistance MINIMUM = MAXIMUM 250 Ohms Per Inch = 1000 Ohms Per Inch 3000 Ohms Per Foot = 12,000 Ohms Per Foot To test ignition coil-to-distributor cap cab]e, do not remove the cable from the cap. Connect ohmmeter to rotor button (center contact) of distributor cap and terminal at ignition coil end of cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, remove the cable from the distributor cap. Connect the ohmmeter to the terminal ends of the cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, replace the cable. Inspect the ignition coil tower for cracks, burns or corrosion. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 3097 Ignition Cable: Service and Repair REMOVAL AND INSTALLATION Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Engine Firing Order Install cables into the proper engine cylinder firing order. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations Accessory Drive Belt Tensioner,coil Mounting Bolt,ignition Coil,coil Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 3101 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 3102 Ignition Coil: Description and Operation SYSTEM OPERATION Battery voltage is supplied to the ignition coil positive terminal from the Automatic Shutdown (ASD) relay. The Powertrain Control Module (PCM) opens and closes the ignition coil ground circuit for ignition coil operation. Base ignition timing is not adjustable on any engine. By controlling the coil ground circuit, the PCM is able to set the base timing and adjust the ignition timing advance. This is done to meet changing engine operating conditions. The ignition coil is not oil filled. The windings are embedded in an epoxy compound. This provides heat and vibration resistance that allows the ignition coil to be mounted on the engine. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Ignition Coil Test Ignition Coil: Testing and Inspection Ignition Coil Test To perform a complete test of the ignition coil and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. To test the coil only, refer to the following: Ignition Coil - Typical The ignition coil is designed to operate without an external ballast resistor. Ignition Coil Resistance Coil Manufacturer = Diamond Primary resistance 21 - 27°C (70 - 80°F) = 0.97 - 1.18 Ohms Secondary resistance 21 - 27°C (70 - 80°F) = 11,300 - 15,300 Ohms Coil Manufacturer = Toydenso Primary resistance 21 - 27°C (70 - 80°F) = 0.95 - 1.20 Ohms Secondary resistance 21 - 27°C (70 - 80°F) = 11,300 - 13,300 Ohms Inspect the ignition coil for arcing. Test the coil according to coil tester manufacturer's instructions. Test the coil primary and secondary resistance. Replace any coil that does not meet specifications. Refer to the IGNITION COIL RESISTANCE chart. If the ignition coil is being replaced, the secondary spark plug cable must also be checked. Replace cable if it has been burned or damaged. Arcing at the tower will carbonize the cable boot, which if it is connected to a new ignition coil, will cause the coil to fail. If the secondary coil cable shows any signs of damage, it should be replaced with a new cable and new terminal. Carbon tracking on the old cable can cause arcing and the failure of a new ignition coil. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Ignition Coil Test > Page 3105 Ignition Coil: Testing and Inspection Testing For Spark at Coil Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (112 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Checking For Spark - Typical 1. Disconnect the ignition coil secondary cable from center tower of tile distributor cap. Hold the cable terminal approximately 12 mm (1/2 in.) from a good engine ground. WARNING: BE VERY CAREFUL WHEN THE ENGINE IS CRANKING. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE FITTING CLOTHING. 2. Rotate (crank) the engine with the starter motor and observe the cable terminal for a steady arc. If steady arcing does not occur, inspect tile secondary coil cable. Refer to Spark Plug Cables. Also inspect the distributor cap and rotor for cracks or burn marks. Repair as necessary. If steady arcing occurs, connect ignition coil cable to the distributor cap. 3. Remove a cable from one spark plug. 4. Using insulated pliers, hold the cable terminal approximately 12 mm (1/2 in.) from the engine cylinder head or block while rotating the engine with the starter motor. Observe the spark plug cable terminal for an arc. If steady arcing occurs, it can be expected that the ignition secondary system is operating correctly (If the ignition coil cable is removed for this test, instead of a spark plug cable, the spark intensity will be much higher). If steady arcing occurs at the spark plug cables, but the engine will not start, connect the DRB scan tool. Refer to the appropriate Powertrain Diagnostic Procedures service. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Page 3106 Ignition Coil: Service and Repair The ignition coil is an epoxy filled type. If the coil is replaced, it must be replaced with the same type. REMOVAL Ignition Coil The coil is mounted to a bracket that is bolted to the front of the right engine cylinder head. This bracket is also used to mount the automatic belt tensioner. 1. Disconnect the wiring and secondary cable from the ignition coil. WARNING: DO NOT REMOVE THE COIL MOUNTING BRACKET-TO-CYLINDER HEAD MOUNTING BOLTS. THE COIL MOUNTING BRACKET IS UNDER ACCESSORY DRIVE BELT TENSION. IF THIS BRACKET IS TO BE REMOVED FOR ANY REASON, ALL BELT TENSION MUST FIRST BE RELIEVED. 2. Remove ignition coil from coil mounting bracket (two bolts). INSTALLATION 1. Install the ignition coil to coil bracket. If nuts and bolts are used to secure coil to coil bracket, tighten to 11 N.m (100 in. lbs.) torque. If the coil mounting bracket has been tapped for coil mounting bolts, tighten bolts to 5 N.m (50 in. lbs.) torque. 2. Connect all wiring to ignition coil. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3111 Camshaft Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3112 Camshaft Position Sensor: Description and Operation SYSTEM OPERATION The camshaft position sensor is located in the distributor on all engines. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3113 Camshaft Position Sensor: Testing and Inspection Camshaft Position Sensor - Typical The camshaft position sensor is located in the distributor on all engines. To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostics Procedures service. To test the sensor only, refer to the following: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Remove engine cover. 2. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. For wire identification. 3. Connect the negative (-) voltmeter lead into the ground wire. For wire identification. 4. Set the voltmeter to the 15 Volt DC scale. 5. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 6. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 7. If voltage is not present, check the voltmeter leads for a good connection. 8. If voltage is still not present, check for voltage at the supply wire. For wire identification. 9. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 10. If voltage is still not present, perform vehicle test using the DRB scan tool. 11. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM. If continuity is not present, repair the harness as necessary c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 12. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3114 Camshaft Position Sensor: Service and Repair The camshaft position sensor is located in the distributor. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove engine cover. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. Crankshaft Position Sensor 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Mounting Bolts 8 Nm Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3118 Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3119 Crankshaft Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3120 Crankshaft Position Sensor: Description and Operation SYSTEM OPERATION Sensor Operation Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. On this engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3121 Crankshaft Position Sensor: Testing and Inspection To perform a complete test of this sensor and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3122 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor - Typical The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. 1. Remove engine cover. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 N.m (70 in.lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For electrical diagnosis of the Key-In-Switch, For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Replacement. On vehicles equipped with an automatic transmission and a steering column mounted shifter, an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. On vehicles equipped with an automatic transmission and a floor mounted shifter, a cable connects the interlock device within the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. The shifter interlock cable can be adjusted or replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 3127 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative battery cable from battery. 2. Place shifter in PARK position. 3. Remove tilt-wheel lever (pulls out). Lower Shroud Screws 4. Remove 2 lower shroud screws (size T25). Shroud Pivot Point 5. Upper and lower shrouds are snapped together at sides. Pivot points for lower and upper shrouds is at rear of shrouds. Lower shroud is hooked to pins on upper shroud. Tilt lower shroud down for removal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 3128 Upper Shroud Screws 6. Remove 2 upper shroud screws (size T5) and remove upper shroud from steering column. 7. If removing key lock cylinder only, proceed to next step. If removing ignition switch, proceed to IGNITION SWITCH REMOVAL. 8. KEY LOCK CYLINDER REMOVAL: Ignition key must be in key cylinder for cylinder removal. a. Rotate and hold key in START position. Lock Cylinder Retainer Pin Access Hole b. Position a 1/16" pin punch into lock cylinder retainer pin access hole. c. Press in on pin punch to release lock cylinder retainer pin while releasing key to RUN position. d. Pull lock cylinder out for removal. 9. IGNITION SWITCH REMOVAL: Key lock cylinder removal is not necessary for ignition switch removal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 3129 Installing Lock Cylinder To Column Removing/Installing Alarm Switch a. Remove alarm switch. Alarm switch is located at right/upper side of steering column. Press on retaining clip with a small screwdriver while rotating switch 1/4 turn for removal. b. Remove knee blocker below steering column. Refer to Knee Blocker in Instrument Panel Gauges And Warning Indicator. c. Note position of wiring harnesses and all tie wraps between ignition switch and 4 way connector at lower part of steering column. when installing ignition switch/wire harness assembly, the harnesses must be correctly routed with tie wraps in correct position to prevent damage to harness. d. If equipped with overdrive (OD) transmission, unclip OD wire harness at ignition switch. e. Cut necessary tie wraps. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 3130 Ignition Switch Mounting Screws f. Remove 2 ignition switch mounting screws (size T4) and separate switch at steering column. Separating 48-Way Connectors At Lower Part Of Column g. Separate steering column 48-way electrical connectors by removing one fastener (bolt). The 48-way connector is located near lower part of steering column. This 48-way connector contains 48 different pin-outs including 3 different connectors: a 17-way for the multi-function switch; a 13-way for the multi-function switch; and an 18-way for the ignition switch. Separating 48-Way Connectors At Lower Part Of Column h. Separate 17-way multi-function switch connector from 18-way ignition switch connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 3131 Steering Column 48-Way Connector (Male C0nnector To Column Shown) i. Separate 13-way multi-function switch connector from 18-way ignition switch connector. j. Separate multi-function switch wire harnesses from ignition switch wiring harness. k. Remove wiring harness and ignition switch as an assembly from steering column. INSTALLATION 1. KEY LOCK CYLINDER INSTALLATION: a. Place key into lock cylinder. b. Place key lock cylinder into steering column by aligning positioning tab on lock cylinder to positioning slot on steering column. Locking tab should also be aligned to locking tab slot. c. Press on lock cylinder until retaining pin engages. d. Rotate key to OFF position. e. Check for proper retention of lock cylinder by attempting to pull out on lock cylinder. 2. IGNITION SWITCH INSTALLATION: a. Position switch and wire harness assembly to steering column. b. Install switch screws and tighten to 1.4 N.m (12 in. lbs.) torque. c. Carefully route ignition switch wire harness down to bottom of steering column. d. If equipped with overdrive (OD) transmission, clip OD wire harness to ignition switch. e. Route alarm switch wire harness around ignition switch. f. Attach alarm switch to steering column by rotating and snapping into position). g. Attach 13-way multi-function switch connector to ignition switch 18-way connector. h. Attach 17-way multi-function switch connector to ignition switch 18-way connector. i. Attach both 48-way electrical connectors together (1 bolt). Tighten bolt to 7 N.m (62 in. lbs.) torque. j. Install new tie wraps in their previously noted positions. k. If equipped with a tilt steering wheel, operate tilt mechanism while observing wiring harnesses for binding. Correct binding if necessary. l. Operate shift lever while observing wiring harnesses for binding. Correct binding if necessary. 3. A 2-5/8" long plastic spacer is attached to inside of upper shroud. Before positioning shroud to column, verify spacer is tightened to upper shroud. 4. Position upper shroud to steering column. 5. Install 2 upper shroud screws. 6. Position rubber shields for shift lever and multi-function switch into upper shroud. 7. Position lower shroud hooks into pins on upper shroud. 8. Snap lower shroud to upper shroud. 9. Install 2 lower shroud screws. 10. Install tilt-wheel lever (snaps in). 11. Shifter should lock in PARK position when key is in LOCK position. Shifter should unlock when key rotated to ON position. 12. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 13. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify Steering wheel should unlock when key is rotated to ON position. 14. Connect negative battery cable to battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... ..................................................... 0.89 mm (0.035 in) Torque ............................................................ ............................................................................................................................................... 41 Nm (30 ft lb) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3135 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ..................................................................... RC12YC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3136 Spark Plug: Description and Operation SYSTEM OPERATION All engines use resistor type spark plugs. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Spark plugs that have low milage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3137 Spark Plug: Testing and Inspection Normal Operating Spark Plug Cable Resistance The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Cold Fouling/Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operating times (short trips). Wet Fouling Or Gas Fouling A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Oil Or Ash Encrusted Oil Or Ash Encrusted If one or more spark plugs are oil or oil ash encrusted, evaluate engine condition for the cause of oil entry into that particular combustion chamber. Electrode Gap Bridging Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3138 Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Scavenger Deposits Scavenger Deposit Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy, but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Chipped Electrode Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Preignition Damage Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3139 Preignition Damage Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Spark Plug Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3140 Spark Plug: Service and Repair Heat Shields Spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. PLUG REMOVAL 1. Remove engine cover. 2. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result, 3. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber. 4. Remove the spark plug using a quality socket with a rubber or foam insert. 5. Inspect the spark plug condition. Plug Cleaning The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator arid will cause plug misfire. Plug Gap Adjustment Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. Spark Plug Gap V-8 Engines: 1.01 mm (.040 in). PLUG INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. when replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 N.m (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations > Component Locations O/D Solenoid,TCC Solenoid,governor Pressure Sensor,governor Pressure Solenoid Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations > Component Locations > Page 3148 Solenoid Case Connector,park/neutral Position Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations > Page 3149 Transmission Solenoid Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3158 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3164 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 3172 Park/Neutral Position Switch Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3173 Torque Convertor Clutch Solenoid Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation SYSTEM OPERATION The overdrive-off indicator lamp gives the driver an indication that the automatic transmission overdrive has been locked out. The lamp is controlled by the Powertrain Control Module (PCM) on a hard wired circuit to instrument cluster. The PCM receives an input from the momentary overdrive lockout switch, which is located on the end of the automatic transmission gearshift selector lever. The PCM uses the overdrive lockout switch input, along with numerous other sensor inputs and its internal programming to decide whether the over-drive-off indicator lamp should be on or off. The PCM then turns the lamp on or off by controlling the ground path for the lamp control circuit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 3179 Overdrive Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative overdrive-off indicator lamp condition. If the overdrive-off indicator lamp comes on and stays on with the engine running, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) and the transmission control system circuits. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Unplug the gray PCM wire harness connector. Install a jumper wire between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. Connect the battery negative cable. Turn the ignition switch to the On position. The overdrive-off indicator lamp should light. Remove the jumper wire and the lamp should turn off. If OK, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) and the transmission control system circuits. If not OK, go to Step 5. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the instrument cluster. Check for continuity between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the short circuit as required. 5. Check for continuity between the overdrive lamp driver circuit cavities of the gray PCM wire harness connector and the instrument cluster wire harness connector (connector A). There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3190 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3191 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3197 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3198 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3199 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3203 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3204 Transmission Control Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 3215 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 3221 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3225 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation TRANSMISSION SPEED SENSOR Transmission Output Speed Sensor The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The rear wheel speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM Technical Service Bulletin # 831 Date: 990601 Recall - Reprogram PCM June 1999 California Emissions Recall No. 831 Reprogram Powertrain Control Module Models 1998 (DN) Dodge Durango (with a 5.9L engine and automatic transmission) (AB) Dodge Ram Van/Wagon (with a 5.9L engine and automatic transmission) (ZJ) Jeep(R) Grand Cherokee (with a 5. 9L engine and automatic transmission) (AN) Dodge Dakota (with 5.2L engine and manual transmission or 5.9L engine and automatic transmission) (BR/BE)Dodge Ram Pickup (with a 5.2L engine and manual transmission, 5.9L engine and automatic transmission or 8.0L engine) NOTE: This recall applies only to certain vehicles equipped with a California emission control system (sales code NAE) built through April 30, 1998 (MDH 0430XX). Subject The On-Board Diagnostic (OBD) system on about 18,000 of the above vehicles may not detect evaporative emissions purge system malfunctions as required by California Emission Regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update labels and Authorized Modifications labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance PCM Update Previously Performed 08831181 0.2 hours Reprogram Powertrain Control Module 08831182 0.5 hours Add the cost of the labels plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 3240 Not Applicable Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD831". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure The DRB III(R) with either MDS1 or MDS2 is required to perform this repair. ^ If using the MDS1 and DRB III, the MDS must be operating at release 21 or higher and TIL CD release 1184 or higher must be installed. ^ If using the MDS2 and DRB III, the system must be operating at CIS CD2034 or higher. Using the MDS1 1. Connect the MDS1 (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 - CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU screen. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III UPDATE on the DRB III MAIN MENU. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER REPROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS1 AND DRB III on the MDS1, then press NEXT MENU. 7. FOLLOW THE STEPS PRESENTED ON THE MDS1 and DRB III that will allow the DRB III to obtain the current part number of the PCM. 8. The MDS1 will display the part number of the PCM on the vehicle and the appropriate replacement part number(s). Press NEXT MENU to begin programming. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 3241 9. The MDS and DRB III will prompt the operator for any action needed during the remainder of the programming process. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Step C. Using the MDS2 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. B. Install Authorized Software Update Label Fig. 1 Type or print (with a ballpoint pen) the necessary information on the "Authorized Software Update" label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Label Fig. 2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 3242 Type or print (with a ballpoint pen) the necessary information shown in Figure 2 onto the Authorized Modifications Label. Then attach the label near the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Owner Letter EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE Dear DaimlerChrysler Vehicle Owner: DaimlerChrysler has determined that some 1998 Dodge Dakota, Durango, Ram Van/Wagon, Ram Truck, and Jeep(R) Grand Cherokee vehicles, equipped with a V-8 or V-10 engine, may be in violation of California Emissions Regulations. The problem is... The On-Board Diagnostic (OBD) system on your vehicle (identified on the enclosed form) may not detect evaporative emissions purge system malfunctions as required by California Emissions Regulations. As a result, the OBD system on your vehicle may not illuminate the "Check Engine" light if the evaporative emissions purge system malfunctions. This could cause your vehicle to emit hydrocarbon levels above the limits that were established to protect the public health from the dangers of air pollution. Hydrocarbons (unburned fuel) combined with oxides of nitrogen, in the presence of sunlight, can cause the formation of ozone. These pollutants are the primary components of smog. What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will reprogram your vehicle's powertrain control module. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer right away to schedule a service appointment. ^ Bring the enclosed Owner Notification form with you to your dealer. It identifies the required service to the dealer. If you live in California and don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. How the state knows that the recall has been performed... State of California regulations require DaimlerChrysler to provide the Department of Motor Vehicles with a record of all vehicles that have not had the recall service performed. If you live in the state of California and your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. In order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. We are sorry for any inconvenience but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you for your attention to this important matter. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-05-00G > Dec > 00 > Engine - Spark Knock/PCM Reprogramming PROM - Programmable Read Only Memory: Customer Interest Engine - Spark Knock/PCM Reprogramming NUMBER: 18-05-00 Rev. G GROUP: Vehicle Performance DATE: Dec. 01, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-05-00 REV F, DATED SEPT. 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN UPDATE TO THE EMISSIONS PACKAGES. SUBJECT: 1998 M.Y. Engine Spark Knock OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 98Cal12 and 98Cal12C) MODELS: 1998 (AB) Ram Van 1998 (AN) Dakota 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1998 (XJ) Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.5L (EPE), 3.9L (EHC), 4.0L (ERH), 5.2L (ELF), OR 5.9L LIGHT DUTY (EML) GASOLINE ENGINE. SEE THE TWO TABLES FOR SPECIFIC APPLICATIONS AND EXCLUSIONS. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-05-00G > Dec > 00 > Engine - Spark Knock/PCM Reprogramming > Page 3248 NOTE: THE FOLLOWING EMISSION PACKAGES ARE NOT APPROVED AND ARE EXCLUDED FROM THIS BULLETIN. THE PCM CALIBRATION OF ANY EXCLUDED VEHICLE IS NOT TO BE REPROGRAMMED FOR A SPARK KNOCK COMPLAINT. BEFORE ATTEMPTING A REPROGRAMMING SESSION INSPECT THE TYPE OF VEHICLE AND ENGINE FOR POSSIBLE EXCLUSION. SYMPTOM/CONDITION: Some vehicle engines may exhibit a light-to-moderate spark knock condition during acceleration (under load). DIAGNOSIS PROCEDURES: 1. Verify that the following NOTE(s) have been reviewed and completed as necessary. 2. Verify that the engine coolant contains a quality antifreeze. The coolant mixture should consist of 44% to 68% antifreeze. 3. If the only condition seen is the light-to-moderate engine spark knock, then perform the Repair Procedure. NOTE: VERIFY THAT TSB 18-48-98, FOR ENGINE IGNITION WIRE ROUTING, HAS BEEN COMPLETED NOTE: THIS REPAIR PROCEDURE WILL NOT COMPENSATE FOR HEAVY SPARK KNOCK CONDITIONS. IF HEAVY KNOCK IS EXPERIENCED, FURTHER DIAGNOSIS AND TESTING OF THE ENGINE WILL BE REQUIRED. REFER TO TSB 09-05-00 FOR ADDITIONAL ASSISTANCE. NOTE: WHEN PULLING A HEAVY LOAD OR DRIVING A FULLY LOADED VEHICLE USE A PREMIUM UNLEADED FUEL TO HELP MINIMIZE SPARK KNOCK. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: EQUIPMENT REQUIRED: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-05-00G > Dec > 00 > Engine - Spark Knock/PCM Reprogramming > Page 3249 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR, WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2069 OR HIGHER (SEE THE TABLE). REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK"BUTTON WHEN ASKED TO BEGIN SESSION. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-05-00G > Dec > 00 > Engine - Spark Knock/PCM Reprogramming > Page 3250 8. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Could be one or more Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-05-00F > Sep > 00 > Engine - Spark Knock on Acceleration PROM - Programmable Read Only Memory: Customer Interest Engine - Spark Knock on Acceleration NUMBER: 18-05-00 Rev F GROUP: Vehicle Performance DATE: September 15, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-05-00 REV E, DATED SEPTEMBER 01, 2000 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN EMISSIONS PACKAGE UPDATE TO THE TABLE. SUBJECT: 1998 Model Year Engine Spark Knock OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 98Cal12 and 98Cal12C) MODELS: 1998 (AB) Ram Van 1998 (AN) Dakota 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1998 (XJ) Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A GASOLINE ENGINE. SEE THE TABLE FOR SPECIFIC APPLICATION. SYMPTOM/CONDITION: Some vehicle engines may exhibit a light-to-moderate spark knock condition during acceleration (under load). DIAGNOSIS: 1. Verify that the following NOTE(S) have been reviewed and completed as necessary. 2. Verify that the engine coolant contains the correct mixture of a quality antifreeze to water. The coolant mixture should consist of 44% to 68% antifreeze. 3. If the only condition seen is the light-to-moderate engine spark knock, perform the Repair Procedure. NOTE: VERIFY THAT TSB 18-48-98 HAS BEEN COMPLETED. NOTE: THIS FEATURE WILL NOT COMPENSATE FOR HEAVY SPARK KNOCK CONDITIONS. IF HEAVY KNOCK IS EXPERIENCED, FURTHER DIAGNOSIS AND TESTING WILL BE REQUIRED. REFER TO TSB 09-05-00 FOR ADDITIONAL ASSISTANCE. NOTE: WHEN PULLING A HEAVY LOAD OR DRIVING A FULLY LOADED VEHICLE USE A PREMIUM UNLEADED FUEL TO HELP Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-05-00F > Sep > 00 > Engine - Spark Knock on Acceleration > Page 3255 MINIMIZE SPARK KNOCK. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2064 OR HIGHER (SEE THE TABLE). REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 3. Select the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE A MESSAGE WILL APPEAR (AFTER STEP 3 OR 4) THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (TCM, BCM, MIC, SKIM, ECT.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED.CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-05-00F > Sep > 00 > Engine - Spark Knock on Acceleration > Page 3256 7. Type the necessary information on the "Authorized Software Update Label" P/N 04669020 (figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. 8. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set Technical Service Bulletin # 18-08-00 Date: 000623 MIL ON, Erroneous DTC P0107 Set NUMBER: 18-08-00 GROUP: Vehicle Performance DATE: June 23, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-03-99, DATED FEB. 19, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination Due To DTC P0107 - Map Sensor Voltage Too Low OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18 and 98Cal12). **MODELS:** **1996** - 1998 (AB) Ram Van **1996** - 1998 (AN) Dakota **1996** - 1998 (BR/BE) Ram Truck 1998 (DN) Durango **1997** - 1998 (TJ) Wrangler **1996** - 1998 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINE. SYMPTOM/CONDITION: Erroneous MIL illumination with DTC P0107 - MAP SENSOR VOLTAGE TOO LOW. This may occur during downhill decelerations at altitude or when performing off-road maneuvers when the engine is operating over 1500 rpm. The MIL illuminates due to the monitor running during incorrect parameters. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set > Page 3261 Labor Operation No: 08-19-42-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4 Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the ORB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and ORB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1) Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set > Page 3262 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3267 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3268 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3269 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-36-97 > Dec > 97 > PCM - Incorrect Fault Mature Time for DTC#B7 PROM - Programmable Read Only Memory: Customer Interest PCM - Incorrect Fault Mature Time for DTC#B7 NO: 18-36-97 GROUP: Vehicle Performance DATE: Dec. 31, 1997 SUBJECT: Incorrect Fault Mature Time - DTC $B7 Leak Detection Pump Solenoid Circuit MODELS: 1998 (AB) Ram Van/Wagon 1998 (AN) Dakota 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1998 (SR) Viper Roadster/Coupe 1998 (TJ) Wrangler 1998 (XJ) Cherokee 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO NOV. 20, 1997 (MDH 1120XX) WITH GASOLINE ENGINES AND SALES CODE NAE (CALIFORNIA EMISSIONS). DISCUSSION: Hex code $B7 - LEAK DETECTION PUMP SOLENOID CIRCUIT is a one trip DTC. Its purpose is to detect electrical shorts or opens in the LDP solenoid circuit. The time it takes for this DTC to mature has been determined to take too long. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT PCM SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 0H7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1147 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes) for the condition listed. NOTE: FOR XJ VEHICLES EQUIPPED WITH AN AISIN WARNER TRANSMISSION, DTC $BE (CCD MESSAGE FROM JTEC FAILURE) CAN BE SET WITHIN THE EATX MODULE DUE TO THE PCM FLASH AND THE DTC GENERATED WITHIN THE EATX MAY SET DTC $89 (EATX CONTROLLER DTC PRESENT) WITHIN THE PCM. CHECK FOR AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-36-97 > Dec > 97 > PCM - Incorrect Fault Mature Time for DTC#B7 > Page 3274 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-48-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures Technical Service Bulletin # 21-06-97A Date: 971219 A/T - Overdrive Unavailable in Cold Temperatures NO: 21-06-97 Rev. A GROUP: Transmission DATE: Dec. 19, 1997 SUBJECT: Overdrive Unavailable in Extreme Cold Temperatures, Bypass Kit Installation, Inhibitor Programming THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-06-97, DATED MAR. 21, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE MARKED WITH **ASTERISKS** AND INCLUDE MODEL CHANGES AND PART NUMBER ADDITIONS FOR V-10 APPLICATIONS. MODELS: 1996 - **1998** (AB) Ram Van/Wagon 1996 (AN) Dakota 1996 - **1998** (BRIBE) Ram Truck 1996 - **1998** (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES AND A 42RE, 44RE, 46RE, OR 47RE TRANSMISSION. SYMPTOM/CONDITION: At ambient temperatures of -20 C (-5 F) or below, the Powertrain Control Module (PCM) will electronically inhibit the transmission from shifting into overdrive. This will protect the transmission from damage if the transmission fluid begins to freeze. In extreme cold climatic regions, this feature can cause customer dissatisfaction due to elimination of overdrive and less than optimal fuel economy. DIAGNOSIS: The cold weather by-pass kit along with disabling the inhibitor feature should only be incorporated for vehicles used in areas of extended cold ambient temperatures. NOTE: THIS KIT WILL DECREASE THE MAXIMUM COOLING CAPACITY OF THE TRANSMISSION'S COOLING SYSTEM. AS A RESULT, IT IS NOT RECOMMENDED THAT THIS BULLETIN BE PERFORMED UNLESS THE ABOVE STATED CONDITION EXISTS. ALSO, IF THE VEHICLE IS USED FOR MODERATE TO HEAVY TOWING IT IS NOT RECOMMENDED. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3279 PARTS/EQUIPMENT REQUIRED: **1 04798668 Kit, By-Pass V-10 Applications** 1 04874284 Kit, Universal By-Pass (See Figure 1 for kit contents) AR(1) 04318044 Thread Sealant 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE ALSO REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3280 WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves installing a cold weather by-pass kit to the transmission cooler circuit, selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes for 1996 models only), and using the DRB III to selectively turn off the overdrive inhibitor feature for all applications. NOTE: IT IS ESSENTIAL THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. NOTE: EVEN WITH BYPASS KIT INSTALLATION AND THE INHIBITOR FEATURE TURNED OFF, 4TH GEAR WILL BE INHIBITED UNTIL THE OIL SUMP TEMPERATURE REACHES 0 C (30 F). THIS MAY TAKE SEVERAL MINUTES. Bypass Kit Installation 1. Record all radio pre-sets and disconnect the negative battery cable. 2. Raise the vehicle for access to the transmission housing. The bypass assembly will be connected to the existing transmission lines and mounted to the transmission housing by means of a bypass adapter. 3. During this installation procedure, some transmission fluid will be lost when the transmission cooler lines are cut (allowing bypass assembly installation). Take proper precautions and check transmission fluid fill level upon completing the installation. 4. It the cold weather bypass kit has provision for an in-line temperature sensor, the threaded "therm-o-well" (in the pressure "P" line of the kit) must be plugged with either the temperature sensor from the existing transmission line or the standard pipe plug provided. Consequently, if the vehicle being serviced is equipped with a temperature sensor (i.e., heavy duty BR truck), remove the temperature sensor from the existing line by un-threading and install it in the "pressure" line provided with the kit. Use Mopar Thread Sealant, p/n 04318044, to ensure a leak free seal. 5. Disconnect the pressure and return lines from the transmission housing fittings. 6. Remove and discard the fittings from the transmission housing. 7. Apply Mopar Thread Sealant, p/n 04318044, to the threaded bypass adapter (# 2 Figure 1). 8. Install the threaded bypass adapter securely into the front pressure port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). 9. Make sure the snap ring and O-ring are properly installed in their respective grooves on the nose of the bypass assembly block. Lubricate the O-ring with ATF. 10. Position the bypass assembly block such that the return port fitting "R" is pointed directly up and the two other fittings are pointed forward. 11. Firmly press the male nose of the bypass assembly into the female body of the threaded bypass adapter until it snaps into place. After snapping into place, the bypass assembly is permanently attached to the adapter. NOTE: THE BYPASS ASSEMBLY CAN ROTATE INSIDE THE ADAPTER, AND REMOVAL OF THE BLOCK FROM THE TRANSMISSION HOUSING (IF REQUIRED) CAN BE ACCOMPLISHED BY UN-THREADING THE ADAPTER. CAUTION: IF FLUSHING THE BYPASS ASSEMBLY IS REQUIRED, IT MUST BE REMOVED FROM THE TRANSMISSION HOUSING AND FORWARD FLUSHED ONLY. FAILING TO REMOVE THE VALVE AND REVERSE FLUSHING WILL RESULT IN TRANSMISSION FAILURE BY PLUGGING THE BYPASS VALVES INTERNAL ORIFICE AND DRAIN BACK VALVE. 12. Apply Mopar Thread Sealant, p/n 04318044, to the threaded end (transmission housing end) of the compression fitting. 13. Install the threaded compression fitting securely into the rear return port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3281 14. Using a small tubing cutter, cut the existing pressure line at approximately 120 mm (5 in.) from the transmission housing end. Repeat the procedure for the existing return line. CAUTION: AFTER CUTTING THE PRESSURE LINE, MARK IT WITH A PIECE OF TAPE FOR IDENTIFICATION. 15. Identify the proper return line ("R" line) by using the marked labels attached to the tubes. 16. Connect the "R" line to the bypass assembly block and the rearward return port of the transmission housing. Tighten the compression fitting finger tight, and then wrench tighten it an additional 1/2 turn. Tighten the inverted flare nut to 6.78 Nm (60 in. lbs.). 17. Select the appropriate "RR" and "P" tubes for the application. Mixing or matching may be required to provide the best routing for your Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3282 application. 18. Loosely connect the pressure line "P" to the pressure port fitting "P" on the bypass assembly block. 19. Loosely connect the radiator return line, "RR" to the "RR" port fitting, on the bypass assembly block. NOTE: DURING THE INSTALLATION OF THE "P" AND "RR" LINES, THE ORDER MAY BE REVERSED TO AID IN THE ASSEMBLY PROCESS. NOTE: ON 5.2L ZJ MODELS, THE THROTTLE VALVE CABLE AND BRACKET MAY REQUIRE REMOVAL FOR BYPASS TUBE CLEARANCE. ONCE THE TUBES ARE INSTALLED LOOSELY, INSTALL THE BRACKET AND THROTTLE VALVE CABLE. MAKE ANY ADJUSTMENTS FOR CLEARANCE AND TIGHTEN THE BYPASS TUBES AND BRACKET ASSEMBLY. 20. Make sure that the existing return line is properly re-attached to the hanger bracket and lay the new return line, "RR", beside it. 21. Install the hose bracket (# 12 in Figure 1) required for the overhead line application. The bracket will replace the existing bracket at the starter mount location. It may require slight modification to provide the best clearance from the exhaust system. 22. Attach clamp (# 11 in Figure 1) and the rubber hose to the "RR" tube to determine the approximate rubber hose routing. For connection to the existing return line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 23. Cut the rubber hose so that it has sufficient length to be attached to the existing return line. 24. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing return line. 25. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 26. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Make modifications as necessary to provide the best routing. 27. Disconnect the "RR" tube from the Bypass Block for access to the "P" port on the block assembly. 28. Attach a clamp and the rubber hose to the "P" tube and determine the approximate rubber hose routing. For connection to the existing pressure line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 29. Cut the rubber hose so that it has sufficient length to be attached to the existing pressure line. 30. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing pressure line. 31. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 32. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Use tie straps and rubber bumpers on the hose to protect the hose from metal surfaces that may cause chaffing. 33. Torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 34. Connect the "RR" ling and torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 35. Re-check to ensure that all connections have been securely tightened and there is sufficient clearance around the exhaust system. 36. If applicable, connect the wire harness to the temperature sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3283 37. Lower the vehicle. 38. Re-connect the negative battery cable and reset the radio stations recorded in step one. 39. Check and adjust the transmission fluid level as outlined in the appropriate Service Manual. 40. Raise the vehicle and check for leaks (idle in Neutral). Flash Programming (1996 Models) NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS UPDATE. THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3284 Programming Cold Overdrive Feature (All Applications) Using the DRB III, use the following procedures to program the overdrive cutoff feature. 1. Connect the DRB III (Scan Tool) to the vehicle and power it up. 2. Use the arrow keys and select # 1 DRB III STANDALONE on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select # 1 1994 - 1998 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU. 4. Use the arrow keys and select # 1 ENGINE on the DRB III SELECT SYSTEM MENU. 5. The module ID screen will appear, press enter to move to next menu. 6. From the SELECT FUNCTION MENU, press the right arrow key for the next page and select # 1 MISCELLANEOUS. 7. From the SELECT MISCELLANEOUS FUNCTION MENU, press the right arrow key for the next page and select # 1 COLD OVERDRIVE FEATURE. 8. Follow the steps presented on the DRB III which will prompt you through the feature selection. 9. When the password is asked for use: 84362172. 10. Follow the remaining prompts for overdrive feature verification. NOTE: IT IS IMPERATIVE THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. Policy/Time Allowance/Failure Code POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-25-17-99-1996 AB/AN/BR/ZJ Models 1.7 Hrs. 21-25-17-99-1997/**1998** AB/BR/BE/ZJ Models 1.5 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3290 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3291 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3292 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3293 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3294 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3295 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3296 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3297 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3298 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3299 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3300 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3301 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3302 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3303 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3304 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3305 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3306 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3307 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3308 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-00G > Dec > 00 > Engine - Spark Knock/PCM Reprogramming PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Spark Knock/PCM Reprogramming NUMBER: 18-05-00 Rev. G GROUP: Vehicle Performance DATE: Dec. 01, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-05-00 REV F, DATED SEPT. 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN UPDATE TO THE EMISSIONS PACKAGES. SUBJECT: 1998 M.Y. Engine Spark Knock OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 98Cal12 and 98Cal12C) MODELS: 1998 (AB) Ram Van 1998 (AN) Dakota 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1998 (XJ) Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.5L (EPE), 3.9L (EHC), 4.0L (ERH), 5.2L (ELF), OR 5.9L LIGHT DUTY (EML) GASOLINE ENGINE. SEE THE TWO TABLES FOR SPECIFIC APPLICATIONS AND EXCLUSIONS. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-00G > Dec > 00 > Engine - Spark Knock/PCM Reprogramming > Page 3313 NOTE: THE FOLLOWING EMISSION PACKAGES ARE NOT APPROVED AND ARE EXCLUDED FROM THIS BULLETIN. THE PCM CALIBRATION OF ANY EXCLUDED VEHICLE IS NOT TO BE REPROGRAMMED FOR A SPARK KNOCK COMPLAINT. BEFORE ATTEMPTING A REPROGRAMMING SESSION INSPECT THE TYPE OF VEHICLE AND ENGINE FOR POSSIBLE EXCLUSION. SYMPTOM/CONDITION: Some vehicle engines may exhibit a light-to-moderate spark knock condition during acceleration (under load). DIAGNOSIS PROCEDURES: 1. Verify that the following NOTE(s) have been reviewed and completed as necessary. 2. Verify that the engine coolant contains a quality antifreeze. The coolant mixture should consist of 44% to 68% antifreeze. 3. If the only condition seen is the light-to-moderate engine spark knock, then perform the Repair Procedure. NOTE: VERIFY THAT TSB 18-48-98, FOR ENGINE IGNITION WIRE ROUTING, HAS BEEN COMPLETED NOTE: THIS REPAIR PROCEDURE WILL NOT COMPENSATE FOR HEAVY SPARK KNOCK CONDITIONS. IF HEAVY KNOCK IS EXPERIENCED, FURTHER DIAGNOSIS AND TESTING OF THE ENGINE WILL BE REQUIRED. REFER TO TSB 09-05-00 FOR ADDITIONAL ASSISTANCE. NOTE: WHEN PULLING A HEAVY LOAD OR DRIVING A FULLY LOADED VEHICLE USE A PREMIUM UNLEADED FUEL TO HELP MINIMIZE SPARK KNOCK. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: EQUIPMENT REQUIRED: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-00G > Dec > 00 > Engine - Spark Knock/PCM Reprogramming > Page 3314 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR, WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2069 OR HIGHER (SEE THE TABLE). REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK"BUTTON WHEN ASKED TO BEGIN SESSION. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-00G > Dec > 00 > Engine - Spark Knock/PCM Reprogramming > Page 3315 8. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Could be one or more Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-00F > Sep > 00 > Engine - Spark Knock on Acceleration PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Spark Knock on Acceleration NUMBER: 18-05-00 Rev F GROUP: Vehicle Performance DATE: September 15, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-05-00 REV E, DATED SEPTEMBER 01, 2000 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN EMISSIONS PACKAGE UPDATE TO THE TABLE. SUBJECT: 1998 Model Year Engine Spark Knock OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 98Cal12 and 98Cal12C) MODELS: 1998 (AB) Ram Van 1998 (AN) Dakota 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1998 (XJ) Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A GASOLINE ENGINE. SEE THE TABLE FOR SPECIFIC APPLICATION. SYMPTOM/CONDITION: Some vehicle engines may exhibit a light-to-moderate spark knock condition during acceleration (under load). DIAGNOSIS: 1. Verify that the following NOTE(S) have been reviewed and completed as necessary. 2. Verify that the engine coolant contains the correct mixture of a quality antifreeze to water. The coolant mixture should consist of 44% to 68% antifreeze. 3. If the only condition seen is the light-to-moderate engine spark knock, perform the Repair Procedure. NOTE: VERIFY THAT TSB 18-48-98 HAS BEEN COMPLETED. NOTE: THIS FEATURE WILL NOT COMPENSATE FOR HEAVY SPARK KNOCK CONDITIONS. IF HEAVY KNOCK IS EXPERIENCED, FURTHER DIAGNOSIS AND TESTING WILL BE REQUIRED. REFER TO TSB 09-05-00 FOR ADDITIONAL ASSISTANCE. NOTE: WHEN PULLING A HEAVY LOAD OR DRIVING A FULLY LOADED VEHICLE USE A PREMIUM UNLEADED FUEL TO HELP Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-00F > Sep > 00 > Engine - Spark Knock on Acceleration > Page 3320 MINIMIZE SPARK KNOCK. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2064 OR HIGHER (SEE THE TABLE). REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 3. Select the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE A MESSAGE WILL APPEAR (AFTER STEP 3 OR 4) THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (TCM, BCM, MIC, SKIM, ECT.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED.CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-00F > Sep > 00 > Engine - Spark Knock on Acceleration > Page 3321 7. Type the necessary information on the "Authorized Software Update Label" P/N 04669020 (figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. 8. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set Technical Service Bulletin # 18-08-00 Date: 000623 MIL ON, Erroneous DTC P0107 Set NUMBER: 18-08-00 GROUP: Vehicle Performance DATE: June 23, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-03-99, DATED FEB. 19, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination Due To DTC P0107 - Map Sensor Voltage Too Low OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18 and 98Cal12). **MODELS:** **1996** - 1998 (AB) Ram Van **1996** - 1998 (AN) Dakota **1996** - 1998 (BR/BE) Ram Truck 1998 (DN) Durango **1997** - 1998 (TJ) Wrangler **1996** - 1998 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINE. SYMPTOM/CONDITION: Erroneous MIL illumination with DTC P0107 - MAP SENSOR VOLTAGE TOO LOW. This may occur during downhill decelerations at altitude or when performing off-road maneuvers when the engine is operating over 1500 rpm. The MIL illuminates due to the monitor running during incorrect parameters. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set > Page 3326 Labor Operation No: 08-19-42-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4 Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the ORB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and ORB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1) Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set > Page 3327 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 831 > Jun > 99 > Recall - Reprogram PCM Technical Service Bulletin # 831 Date: 990601 Recall - Reprogram PCM June 1999 California Emissions Recall No. 831 Reprogram Powertrain Control Module Models 1998 (DN) Dodge Durango (with a 5.9L engine and automatic transmission) (AB) Dodge Ram Van/Wagon (with a 5.9L engine and automatic transmission) (ZJ) Jeep(R) Grand Cherokee (with a 5. 9L engine and automatic transmission) (AN) Dodge Dakota (with 5.2L engine and manual transmission or 5.9L engine and automatic transmission) (BR/BE)Dodge Ram Pickup (with a 5.2L engine and manual transmission, 5.9L engine and automatic transmission or 8.0L engine) NOTE: This recall applies only to certain vehicles equipped with a California emission control system (sales code NAE) built through April 30, 1998 (MDH 0430XX). Subject The On-Board Diagnostic (OBD) system on about 18,000 of the above vehicles may not detect evaporative emissions purge system malfunctions as required by California Emission Regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update labels and Authorized Modifications labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance PCM Update Previously Performed 08831181 0.2 hours Reprogram Powertrain Control Module 08831182 0.5 hours Add the cost of the labels plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 3332 Not Applicable Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD831". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure The DRB III(R) with either MDS1 or MDS2 is required to perform this repair. ^ If using the MDS1 and DRB III, the MDS must be operating at release 21 or higher and TIL CD release 1184 or higher must be installed. ^ If using the MDS2 and DRB III, the system must be operating at CIS CD2034 or higher. Using the MDS1 1. Connect the MDS1 (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 - CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU screen. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III UPDATE on the DRB III MAIN MENU. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER REPROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS1 AND DRB III on the MDS1, then press NEXT MENU. 7. FOLLOW THE STEPS PRESENTED ON THE MDS1 and DRB III that will allow the DRB III to obtain the current part number of the PCM. 8. The MDS1 will display the part number of the PCM on the vehicle and the appropriate replacement part number(s). Press NEXT MENU to begin programming. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 3333 9. The MDS and DRB III will prompt the operator for any action needed during the remainder of the programming process. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Step C. Using the MDS2 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. B. Install Authorized Software Update Label Fig. 1 Type or print (with a ballpoint pen) the necessary information on the "Authorized Software Update" label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Label Fig. 2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 3334 Type or print (with a ballpoint pen) the necessary information shown in Figure 2 onto the Authorized Modifications Label. Then attach the label near the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Owner Letter EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE Dear DaimlerChrysler Vehicle Owner: DaimlerChrysler has determined that some 1998 Dodge Dakota, Durango, Ram Van/Wagon, Ram Truck, and Jeep(R) Grand Cherokee vehicles, equipped with a V-8 or V-10 engine, may be in violation of California Emissions Regulations. The problem is... The On-Board Diagnostic (OBD) system on your vehicle (identified on the enclosed form) may not detect evaporative emissions purge system malfunctions as required by California Emissions Regulations. As a result, the OBD system on your vehicle may not illuminate the "Check Engine" light if the evaporative emissions purge system malfunctions. This could cause your vehicle to emit hydrocarbon levels above the limits that were established to protect the public health from the dangers of air pollution. Hydrocarbons (unburned fuel) combined with oxides of nitrogen, in the presence of sunlight, can cause the formation of ozone. These pollutants are the primary components of smog. What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will reprogram your vehicle's powertrain control module. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer right away to schedule a service appointment. ^ Bring the enclosed Owner Notification form with you to your dealer. It identifies the required service to the dealer. If you live in California and don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. How the state knows that the recall has been performed... State of California regulations require DaimlerChrysler to provide the Department of Motor Vehicles with a record of all vehicles that have not had the recall service performed. If you live in the state of California and your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. In order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. We are sorry for any inconvenience but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you for your attention to this important matter. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3339 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3340 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3341 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-36-97 > Dec > 97 > PCM - Incorrect Fault Mature Time for DTC#B7 PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Incorrect Fault Mature Time for DTC#B7 NO: 18-36-97 GROUP: Vehicle Performance DATE: Dec. 31, 1997 SUBJECT: Incorrect Fault Mature Time - DTC $B7 Leak Detection Pump Solenoid Circuit MODELS: 1998 (AB) Ram Van/Wagon 1998 (AN) Dakota 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1998 (SR) Viper Roadster/Coupe 1998 (TJ) Wrangler 1998 (XJ) Cherokee 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO NOV. 20, 1997 (MDH 1120XX) WITH GASOLINE ENGINES AND SALES CODE NAE (CALIFORNIA EMISSIONS). DISCUSSION: Hex code $B7 - LEAK DETECTION PUMP SOLENOID CIRCUIT is a one trip DTC. Its purpose is to detect electrical shorts or opens in the LDP solenoid circuit. The time it takes for this DTC to mature has been determined to take too long. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT PCM SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 0H7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1147 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes) for the condition listed. NOTE: FOR XJ VEHICLES EQUIPPED WITH AN AISIN WARNER TRANSMISSION, DTC $BE (CCD MESSAGE FROM JTEC FAILURE) CAN BE SET WITHIN THE EATX MODULE DUE TO THE PCM FLASH AND THE DTC GENERATED WITHIN THE EATX MAY SET DTC $89 (EATX CONTROLLER DTC PRESENT) WITHIN THE PCM. CHECK FOR AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-36-97 > Dec > 97 > PCM - Incorrect Fault Mature Time for DTC#B7 > Page 3346 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-48-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures Technical Service Bulletin # 21-06-97A Date: 971219 A/T - Overdrive Unavailable in Cold Temperatures NO: 21-06-97 Rev. A GROUP: Transmission DATE: Dec. 19, 1997 SUBJECT: Overdrive Unavailable in Extreme Cold Temperatures, Bypass Kit Installation, Inhibitor Programming THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-06-97, DATED MAR. 21, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE MARKED WITH **ASTERISKS** AND INCLUDE MODEL CHANGES AND PART NUMBER ADDITIONS FOR V-10 APPLICATIONS. MODELS: 1996 - **1998** (AB) Ram Van/Wagon 1996 (AN) Dakota 1996 - **1998** (BRIBE) Ram Truck 1996 - **1998** (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES AND A 42RE, 44RE, 46RE, OR 47RE TRANSMISSION. SYMPTOM/CONDITION: At ambient temperatures of -20 C (-5 F) or below, the Powertrain Control Module (PCM) will electronically inhibit the transmission from shifting into overdrive. This will protect the transmission from damage if the transmission fluid begins to freeze. In extreme cold climatic regions, this feature can cause customer dissatisfaction due to elimination of overdrive and less than optimal fuel economy. DIAGNOSIS: The cold weather by-pass kit along with disabling the inhibitor feature should only be incorporated for vehicles used in areas of extended cold ambient temperatures. NOTE: THIS KIT WILL DECREASE THE MAXIMUM COOLING CAPACITY OF THE TRANSMISSION'S COOLING SYSTEM. AS A RESULT, IT IS NOT RECOMMENDED THAT THIS BULLETIN BE PERFORMED UNLESS THE ABOVE STATED CONDITION EXISTS. ALSO, IF THE VEHICLE IS USED FOR MODERATE TO HEAVY TOWING IT IS NOT RECOMMENDED. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3351 PARTS/EQUIPMENT REQUIRED: **1 04798668 Kit, By-Pass V-10 Applications** 1 04874284 Kit, Universal By-Pass (See Figure 1 for kit contents) AR(1) 04318044 Thread Sealant 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE ALSO REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3352 WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves installing a cold weather by-pass kit to the transmission cooler circuit, selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes for 1996 models only), and using the DRB III to selectively turn off the overdrive inhibitor feature for all applications. NOTE: IT IS ESSENTIAL THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. NOTE: EVEN WITH BYPASS KIT INSTALLATION AND THE INHIBITOR FEATURE TURNED OFF, 4TH GEAR WILL BE INHIBITED UNTIL THE OIL SUMP TEMPERATURE REACHES 0 C (30 F). THIS MAY TAKE SEVERAL MINUTES. Bypass Kit Installation 1. Record all radio pre-sets and disconnect the negative battery cable. 2. Raise the vehicle for access to the transmission housing. The bypass assembly will be connected to the existing transmission lines and mounted to the transmission housing by means of a bypass adapter. 3. During this installation procedure, some transmission fluid will be lost when the transmission cooler lines are cut (allowing bypass assembly installation). Take proper precautions and check transmission fluid fill level upon completing the installation. 4. It the cold weather bypass kit has provision for an in-line temperature sensor, the threaded "therm-o-well" (in the pressure "P" line of the kit) must be plugged with either the temperature sensor from the existing transmission line or the standard pipe plug provided. Consequently, if the vehicle being serviced is equipped with a temperature sensor (i.e., heavy duty BR truck), remove the temperature sensor from the existing line by un-threading and install it in the "pressure" line provided with the kit. Use Mopar Thread Sealant, p/n 04318044, to ensure a leak free seal. 5. Disconnect the pressure and return lines from the transmission housing fittings. 6. Remove and discard the fittings from the transmission housing. 7. Apply Mopar Thread Sealant, p/n 04318044, to the threaded bypass adapter (# 2 Figure 1). 8. Install the threaded bypass adapter securely into the front pressure port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). 9. Make sure the snap ring and O-ring are properly installed in their respective grooves on the nose of the bypass assembly block. Lubricate the O-ring with ATF. 10. Position the bypass assembly block such that the return port fitting "R" is pointed directly up and the two other fittings are pointed forward. 11. Firmly press the male nose of the bypass assembly into the female body of the threaded bypass adapter until it snaps into place. After snapping into place, the bypass assembly is permanently attached to the adapter. NOTE: THE BYPASS ASSEMBLY CAN ROTATE INSIDE THE ADAPTER, AND REMOVAL OF THE BLOCK FROM THE TRANSMISSION HOUSING (IF REQUIRED) CAN BE ACCOMPLISHED BY UN-THREADING THE ADAPTER. CAUTION: IF FLUSHING THE BYPASS ASSEMBLY IS REQUIRED, IT MUST BE REMOVED FROM THE TRANSMISSION HOUSING AND FORWARD FLUSHED ONLY. FAILING TO REMOVE THE VALVE AND REVERSE FLUSHING WILL RESULT IN TRANSMISSION FAILURE BY PLUGGING THE BYPASS VALVES INTERNAL ORIFICE AND DRAIN BACK VALVE. 12. Apply Mopar Thread Sealant, p/n 04318044, to the threaded end (transmission housing end) of the compression fitting. 13. Install the threaded compression fitting securely into the rear return port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3353 14. Using a small tubing cutter, cut the existing pressure line at approximately 120 mm (5 in.) from the transmission housing end. Repeat the procedure for the existing return line. CAUTION: AFTER CUTTING THE PRESSURE LINE, MARK IT WITH A PIECE OF TAPE FOR IDENTIFICATION. 15. Identify the proper return line ("R" line) by using the marked labels attached to the tubes. 16. Connect the "R" line to the bypass assembly block and the rearward return port of the transmission housing. Tighten the compression fitting finger tight, and then wrench tighten it an additional 1/2 turn. Tighten the inverted flare nut to 6.78 Nm (60 in. lbs.). 17. Select the appropriate "RR" and "P" tubes for the application. Mixing or matching may be required to provide the best routing for your Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3354 application. 18. Loosely connect the pressure line "P" to the pressure port fitting "P" on the bypass assembly block. 19. Loosely connect the radiator return line, "RR" to the "RR" port fitting, on the bypass assembly block. NOTE: DURING THE INSTALLATION OF THE "P" AND "RR" LINES, THE ORDER MAY BE REVERSED TO AID IN THE ASSEMBLY PROCESS. NOTE: ON 5.2L ZJ MODELS, THE THROTTLE VALVE CABLE AND BRACKET MAY REQUIRE REMOVAL FOR BYPASS TUBE CLEARANCE. ONCE THE TUBES ARE INSTALLED LOOSELY, INSTALL THE BRACKET AND THROTTLE VALVE CABLE. MAKE ANY ADJUSTMENTS FOR CLEARANCE AND TIGHTEN THE BYPASS TUBES AND BRACKET ASSEMBLY. 20. Make sure that the existing return line is properly re-attached to the hanger bracket and lay the new return line, "RR", beside it. 21. Install the hose bracket (# 12 in Figure 1) required for the overhead line application. The bracket will replace the existing bracket at the starter mount location. It may require slight modification to provide the best clearance from the exhaust system. 22. Attach clamp (# 11 in Figure 1) and the rubber hose to the "RR" tube to determine the approximate rubber hose routing. For connection to the existing return line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 23. Cut the rubber hose so that it has sufficient length to be attached to the existing return line. 24. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing return line. 25. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 26. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Make modifications as necessary to provide the best routing. 27. Disconnect the "RR" tube from the Bypass Block for access to the "P" port on the block assembly. 28. Attach a clamp and the rubber hose to the "P" tube and determine the approximate rubber hose routing. For connection to the existing pressure line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 29. Cut the rubber hose so that it has sufficient length to be attached to the existing pressure line. 30. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing pressure line. 31. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 32. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Use tie straps and rubber bumpers on the hose to protect the hose from metal surfaces that may cause chaffing. 33. Torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 34. Connect the "RR" ling and torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 35. Re-check to ensure that all connections have been securely tightened and there is sufficient clearance around the exhaust system. 36. If applicable, connect the wire harness to the temperature sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3355 37. Lower the vehicle. 38. Re-connect the negative battery cable and reset the radio stations recorded in step one. 39. Check and adjust the transmission fluid level as outlined in the appropriate Service Manual. 40. Raise the vehicle and check for leaks (idle in Neutral). Flash Programming (1996 Models) NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS UPDATE. THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3356 Programming Cold Overdrive Feature (All Applications) Using the DRB III, use the following procedures to program the overdrive cutoff feature. 1. Connect the DRB III (Scan Tool) to the vehicle and power it up. 2. Use the arrow keys and select # 1 DRB III STANDALONE on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select # 1 1994 - 1998 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU. 4. Use the arrow keys and select # 1 ENGINE on the DRB III SELECT SYSTEM MENU. 5. The module ID screen will appear, press enter to move to next menu. 6. From the SELECT FUNCTION MENU, press the right arrow key for the next page and select # 1 MISCELLANEOUS. 7. From the SELECT MISCELLANEOUS FUNCTION MENU, press the right arrow key for the next page and select # 1 COLD OVERDRIVE FEATURE. 8. Follow the steps presented on the DRB III which will prompt you through the feature selection. 9. When the password is asked for use: 84362172. 10. Follow the remaining prompts for overdrive feature verification. NOTE: IT IS IMPERATIVE THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. Policy/Time Allowance/Failure Code POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-25-17-99-1996 AB/AN/BR/ZJ Models 1.7 Hrs. 21-25-17-99-1997/**1998** AB/BR/BE/ZJ Models 1.5 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3362 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3363 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3364 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3365 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3366 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3367 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3368 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3369 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3370 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3371 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3372 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3373 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3374 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3375 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3376 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3377 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3378 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3379 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3380 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-00G > Dec > 00 > Engine - Spark Knock/PCM Reprogramming PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Spark Knock/PCM Reprogramming NUMBER: 18-05-00 Rev. G GROUP: Vehicle Performance DATE: Dec. 01, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-05-00 REV F, DATED SEPT. 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN UPDATE TO THE EMISSIONS PACKAGES. SUBJECT: 1998 M.Y. Engine Spark Knock OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 98Cal12 and 98Cal12C) MODELS: 1998 (AB) Ram Van 1998 (AN) Dakota 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1998 (XJ) Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.5L (EPE), 3.9L (EHC), 4.0L (ERH), 5.2L (ELF), OR 5.9L LIGHT DUTY (EML) GASOLINE ENGINE. SEE THE TWO TABLES FOR SPECIFIC APPLICATIONS AND EXCLUSIONS. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-00G > Dec > 00 > Engine - Spark Knock/PCM Reprogramming > Page 3385 NOTE: THE FOLLOWING EMISSION PACKAGES ARE NOT APPROVED AND ARE EXCLUDED FROM THIS BULLETIN. THE PCM CALIBRATION OF ANY EXCLUDED VEHICLE IS NOT TO BE REPROGRAMMED FOR A SPARK KNOCK COMPLAINT. BEFORE ATTEMPTING A REPROGRAMMING SESSION INSPECT THE TYPE OF VEHICLE AND ENGINE FOR POSSIBLE EXCLUSION. SYMPTOM/CONDITION: Some vehicle engines may exhibit a light-to-moderate spark knock condition during acceleration (under load). DIAGNOSIS PROCEDURES: 1. Verify that the following NOTE(s) have been reviewed and completed as necessary. 2. Verify that the engine coolant contains a quality antifreeze. The coolant mixture should consist of 44% to 68% antifreeze. 3. If the only condition seen is the light-to-moderate engine spark knock, then perform the Repair Procedure. NOTE: VERIFY THAT TSB 18-48-98, FOR ENGINE IGNITION WIRE ROUTING, HAS BEEN COMPLETED NOTE: THIS REPAIR PROCEDURE WILL NOT COMPENSATE FOR HEAVY SPARK KNOCK CONDITIONS. IF HEAVY KNOCK IS EXPERIENCED, FURTHER DIAGNOSIS AND TESTING OF THE ENGINE WILL BE REQUIRED. REFER TO TSB 09-05-00 FOR ADDITIONAL ASSISTANCE. NOTE: WHEN PULLING A HEAVY LOAD OR DRIVING A FULLY LOADED VEHICLE USE A PREMIUM UNLEADED FUEL TO HELP MINIMIZE SPARK KNOCK. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: EQUIPMENT REQUIRED: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-00G > Dec > 00 > Engine - Spark Knock/PCM Reprogramming > Page 3386 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR, WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2069 OR HIGHER (SEE THE TABLE). REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK"BUTTON WHEN ASKED TO BEGIN SESSION. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-00G > Dec > 00 > Engine - Spark Knock/PCM Reprogramming > Page 3387 8. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Could be one or more Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-00F > Sep > 00 > Engine - Spark Knock on Acceleration PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Spark Knock on Acceleration NUMBER: 18-05-00 Rev F GROUP: Vehicle Performance DATE: September 15, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-05-00 REV E, DATED SEPTEMBER 01, 2000 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN EMISSIONS PACKAGE UPDATE TO THE TABLE. SUBJECT: 1998 Model Year Engine Spark Knock OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 98Cal12 and 98Cal12C) MODELS: 1998 (AB) Ram Van 1998 (AN) Dakota 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1998 (XJ) Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A GASOLINE ENGINE. SEE THE TABLE FOR SPECIFIC APPLICATION. SYMPTOM/CONDITION: Some vehicle engines may exhibit a light-to-moderate spark knock condition during acceleration (under load). DIAGNOSIS: 1. Verify that the following NOTE(S) have been reviewed and completed as necessary. 2. Verify that the engine coolant contains the correct mixture of a quality antifreeze to water. The coolant mixture should consist of 44% to 68% antifreeze. 3. If the only condition seen is the light-to-moderate engine spark knock, perform the Repair Procedure. NOTE: VERIFY THAT TSB 18-48-98 HAS BEEN COMPLETED. NOTE: THIS FEATURE WILL NOT COMPENSATE FOR HEAVY SPARK KNOCK CONDITIONS. IF HEAVY KNOCK IS EXPERIENCED, FURTHER DIAGNOSIS AND TESTING WILL BE REQUIRED. REFER TO TSB 09-05-00 FOR ADDITIONAL ASSISTANCE. NOTE: WHEN PULLING A HEAVY LOAD OR DRIVING A FULLY LOADED VEHICLE USE A PREMIUM UNLEADED FUEL TO HELP Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-00F > Sep > 00 > Engine - Spark Knock on Acceleration > Page 3392 MINIMIZE SPARK KNOCK. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2064 OR HIGHER (SEE THE TABLE). REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 3. Select the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE A MESSAGE WILL APPEAR (AFTER STEP 3 OR 4) THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (TCM, BCM, MIC, SKIM, ECT.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED.CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-00F > Sep > 00 > Engine - Spark Knock on Acceleration > Page 3393 7. Type the necessary information on the "Authorized Software Update Label" P/N 04669020 (figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. 8. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set Technical Service Bulletin # 18-08-00 Date: 000623 MIL ON, Erroneous DTC P0107 Set NUMBER: 18-08-00 GROUP: Vehicle Performance DATE: June 23, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-03-99, DATED FEB. 19, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination Due To DTC P0107 - Map Sensor Voltage Too Low OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18 and 98Cal12). **MODELS:** **1996** - 1998 (AB) Ram Van **1996** - 1998 (AN) Dakota **1996** - 1998 (BR/BE) Ram Truck 1998 (DN) Durango **1997** - 1998 (TJ) Wrangler **1996** - 1998 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINE. SYMPTOM/CONDITION: Erroneous MIL illumination with DTC P0107 - MAP SENSOR VOLTAGE TOO LOW. This may occur during downhill decelerations at altitude or when performing off-road maneuvers when the engine is operating over 1500 rpm. The MIL illuminates due to the monitor running during incorrect parameters. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set > Page 3398 Labor Operation No: 08-19-42-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4 Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the ORB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and ORB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1) Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set > Page 3399 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3404 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3405 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3406 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-36-97 > Dec > 97 > PCM - Incorrect Fault Mature Time for DTC#B7 PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Incorrect Fault Mature Time for DTC#B7 NO: 18-36-97 GROUP: Vehicle Performance DATE: Dec. 31, 1997 SUBJECT: Incorrect Fault Mature Time - DTC $B7 Leak Detection Pump Solenoid Circuit MODELS: 1998 (AB) Ram Van/Wagon 1998 (AN) Dakota 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1998 (SR) Viper Roadster/Coupe 1998 (TJ) Wrangler 1998 (XJ) Cherokee 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO NOV. 20, 1997 (MDH 1120XX) WITH GASOLINE ENGINES AND SALES CODE NAE (CALIFORNIA EMISSIONS). DISCUSSION: Hex code $B7 - LEAK DETECTION PUMP SOLENOID CIRCUIT is a one trip DTC. Its purpose is to detect electrical shorts or opens in the LDP solenoid circuit. The time it takes for this DTC to mature has been determined to take too long. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT PCM SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 0H7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1147 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes) for the condition listed. NOTE: FOR XJ VEHICLES EQUIPPED WITH AN AISIN WARNER TRANSMISSION, DTC $BE (CCD MESSAGE FROM JTEC FAILURE) CAN BE SET WITHIN THE EATX MODULE DUE TO THE PCM FLASH AND THE DTC GENERATED WITHIN THE EATX MAY SET DTC $89 (EATX CONTROLLER DTC PRESENT) WITHIN THE PCM. CHECK FOR AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-36-97 > Dec > 97 > PCM - Incorrect Fault Mature Time for DTC#B7 > Page 3411 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-48-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures Technical Service Bulletin # 21-06-97A Date: 971219 A/T - Overdrive Unavailable in Cold Temperatures NO: 21-06-97 Rev. A GROUP: Transmission DATE: Dec. 19, 1997 SUBJECT: Overdrive Unavailable in Extreme Cold Temperatures, Bypass Kit Installation, Inhibitor Programming THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-06-97, DATED MAR. 21, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE MARKED WITH **ASTERISKS** AND INCLUDE MODEL CHANGES AND PART NUMBER ADDITIONS FOR V-10 APPLICATIONS. MODELS: 1996 - **1998** (AB) Ram Van/Wagon 1996 (AN) Dakota 1996 - **1998** (BRIBE) Ram Truck 1996 - **1998** (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES AND A 42RE, 44RE, 46RE, OR 47RE TRANSMISSION. SYMPTOM/CONDITION: At ambient temperatures of -20 C (-5 F) or below, the Powertrain Control Module (PCM) will electronically inhibit the transmission from shifting into overdrive. This will protect the transmission from damage if the transmission fluid begins to freeze. In extreme cold climatic regions, this feature can cause customer dissatisfaction due to elimination of overdrive and less than optimal fuel economy. DIAGNOSIS: The cold weather by-pass kit along with disabling the inhibitor feature should only be incorporated for vehicles used in areas of extended cold ambient temperatures. NOTE: THIS KIT WILL DECREASE THE MAXIMUM COOLING CAPACITY OF THE TRANSMISSION'S COOLING SYSTEM. AS A RESULT, IT IS NOT RECOMMENDED THAT THIS BULLETIN BE PERFORMED UNLESS THE ABOVE STATED CONDITION EXISTS. ALSO, IF THE VEHICLE IS USED FOR MODERATE TO HEAVY TOWING IT IS NOT RECOMMENDED. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3416 PARTS/EQUIPMENT REQUIRED: **1 04798668 Kit, By-Pass V-10 Applications** 1 04874284 Kit, Universal By-Pass (See Figure 1 for kit contents) AR(1) 04318044 Thread Sealant 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE ALSO REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3417 WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves installing a cold weather by-pass kit to the transmission cooler circuit, selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes for 1996 models only), and using the DRB III to selectively turn off the overdrive inhibitor feature for all applications. NOTE: IT IS ESSENTIAL THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. NOTE: EVEN WITH BYPASS KIT INSTALLATION AND THE INHIBITOR FEATURE TURNED OFF, 4TH GEAR WILL BE INHIBITED UNTIL THE OIL SUMP TEMPERATURE REACHES 0 C (30 F). THIS MAY TAKE SEVERAL MINUTES. Bypass Kit Installation 1. Record all radio pre-sets and disconnect the negative battery cable. 2. Raise the vehicle for access to the transmission housing. The bypass assembly will be connected to the existing transmission lines and mounted to the transmission housing by means of a bypass adapter. 3. During this installation procedure, some transmission fluid will be lost when the transmission cooler lines are cut (allowing bypass assembly installation). Take proper precautions and check transmission fluid fill level upon completing the installation. 4. It the cold weather bypass kit has provision for an in-line temperature sensor, the threaded "therm-o-well" (in the pressure "P" line of the kit) must be plugged with either the temperature sensor from the existing transmission line or the standard pipe plug provided. Consequently, if the vehicle being serviced is equipped with a temperature sensor (i.e., heavy duty BR truck), remove the temperature sensor from the existing line by un-threading and install it in the "pressure" line provided with the kit. Use Mopar Thread Sealant, p/n 04318044, to ensure a leak free seal. 5. Disconnect the pressure and return lines from the transmission housing fittings. 6. Remove and discard the fittings from the transmission housing. 7. Apply Mopar Thread Sealant, p/n 04318044, to the threaded bypass adapter (# 2 Figure 1). 8. Install the threaded bypass adapter securely into the front pressure port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). 9. Make sure the snap ring and O-ring are properly installed in their respective grooves on the nose of the bypass assembly block. Lubricate the O-ring with ATF. 10. Position the bypass assembly block such that the return port fitting "R" is pointed directly up and the two other fittings are pointed forward. 11. Firmly press the male nose of the bypass assembly into the female body of the threaded bypass adapter until it snaps into place. After snapping into place, the bypass assembly is permanently attached to the adapter. NOTE: THE BYPASS ASSEMBLY CAN ROTATE INSIDE THE ADAPTER, AND REMOVAL OF THE BLOCK FROM THE TRANSMISSION HOUSING (IF REQUIRED) CAN BE ACCOMPLISHED BY UN-THREADING THE ADAPTER. CAUTION: IF FLUSHING THE BYPASS ASSEMBLY IS REQUIRED, IT MUST BE REMOVED FROM THE TRANSMISSION HOUSING AND FORWARD FLUSHED ONLY. FAILING TO REMOVE THE VALVE AND REVERSE FLUSHING WILL RESULT IN TRANSMISSION FAILURE BY PLUGGING THE BYPASS VALVES INTERNAL ORIFICE AND DRAIN BACK VALVE. 12. Apply Mopar Thread Sealant, p/n 04318044, to the threaded end (transmission housing end) of the compression fitting. 13. Install the threaded compression fitting securely into the rear return port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3418 14. Using a small tubing cutter, cut the existing pressure line at approximately 120 mm (5 in.) from the transmission housing end. Repeat the procedure for the existing return line. CAUTION: AFTER CUTTING THE PRESSURE LINE, MARK IT WITH A PIECE OF TAPE FOR IDENTIFICATION. 15. Identify the proper return line ("R" line) by using the marked labels attached to the tubes. 16. Connect the "R" line to the bypass assembly block and the rearward return port of the transmission housing. Tighten the compression fitting finger tight, and then wrench tighten it an additional 1/2 turn. Tighten the inverted flare nut to 6.78 Nm (60 in. lbs.). 17. Select the appropriate "RR" and "P" tubes for the application. Mixing or matching may be required to provide the best routing for your Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3419 application. 18. Loosely connect the pressure line "P" to the pressure port fitting "P" on the bypass assembly block. 19. Loosely connect the radiator return line, "RR" to the "RR" port fitting, on the bypass assembly block. NOTE: DURING THE INSTALLATION OF THE "P" AND "RR" LINES, THE ORDER MAY BE REVERSED TO AID IN THE ASSEMBLY PROCESS. NOTE: ON 5.2L ZJ MODELS, THE THROTTLE VALVE CABLE AND BRACKET MAY REQUIRE REMOVAL FOR BYPASS TUBE CLEARANCE. ONCE THE TUBES ARE INSTALLED LOOSELY, INSTALL THE BRACKET AND THROTTLE VALVE CABLE. MAKE ANY ADJUSTMENTS FOR CLEARANCE AND TIGHTEN THE BYPASS TUBES AND BRACKET ASSEMBLY. 20. Make sure that the existing return line is properly re-attached to the hanger bracket and lay the new return line, "RR", beside it. 21. Install the hose bracket (# 12 in Figure 1) required for the overhead line application. The bracket will replace the existing bracket at the starter mount location. It may require slight modification to provide the best clearance from the exhaust system. 22. Attach clamp (# 11 in Figure 1) and the rubber hose to the "RR" tube to determine the approximate rubber hose routing. For connection to the existing return line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 23. Cut the rubber hose so that it has sufficient length to be attached to the existing return line. 24. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing return line. 25. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 26. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Make modifications as necessary to provide the best routing. 27. Disconnect the "RR" tube from the Bypass Block for access to the "P" port on the block assembly. 28. Attach a clamp and the rubber hose to the "P" tube and determine the approximate rubber hose routing. For connection to the existing pressure line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 29. Cut the rubber hose so that it has sufficient length to be attached to the existing pressure line. 30. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing pressure line. 31. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 32. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Use tie straps and rubber bumpers on the hose to protect the hose from metal surfaces that may cause chaffing. 33. Torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 34. Connect the "RR" ling and torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 35. Re-check to ensure that all connections have been securely tightened and there is sufficient clearance around the exhaust system. 36. If applicable, connect the wire harness to the temperature sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3420 37. Lower the vehicle. 38. Re-connect the negative battery cable and reset the radio stations recorded in step one. 39. Check and adjust the transmission fluid level as outlined in the appropriate Service Manual. 40. Raise the vehicle and check for leaks (idle in Neutral). Flash Programming (1996 Models) NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS UPDATE. THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3421 Programming Cold Overdrive Feature (All Applications) Using the DRB III, use the following procedures to program the overdrive cutoff feature. 1. Connect the DRB III (Scan Tool) to the vehicle and power it up. 2. Use the arrow keys and select # 1 DRB III STANDALONE on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select # 1 1994 - 1998 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU. 4. Use the arrow keys and select # 1 ENGINE on the DRB III SELECT SYSTEM MENU. 5. The module ID screen will appear, press enter to move to next menu. 6. From the SELECT FUNCTION MENU, press the right arrow key for the next page and select # 1 MISCELLANEOUS. 7. From the SELECT MISCELLANEOUS FUNCTION MENU, press the right arrow key for the next page and select # 1 COLD OVERDRIVE FEATURE. 8. Follow the steps presented on the DRB III which will prompt you through the feature selection. 9. When the password is asked for use: 84362172. 10. Follow the remaining prompts for overdrive feature verification. NOTE: IT IS IMPERATIVE THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. Policy/Time Allowance/Failure Code POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-25-17-99-1996 AB/AN/BR/ZJ Models 1.7 Hrs. 21-25-17-99-1997/**1998** AB/BR/BE/ZJ Models 1.5 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3427 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3428 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3429 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3430 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3431 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3432 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3433 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3434 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3435 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3436 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3437 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3438 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3439 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3440 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3441 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3442 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3443 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3444 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3445 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 831 > Jun > 99 > Recall - Reprogram PCM Technical Service Bulletin # 831 Date: 990601 Recall - Reprogram PCM June 1999 California Emissions Recall No. 831 Reprogram Powertrain Control Module Models 1998 (DN) Dodge Durango (with a 5.9L engine and automatic transmission) (AB) Dodge Ram Van/Wagon (with a 5.9L engine and automatic transmission) (ZJ) Jeep(R) Grand Cherokee (with a 5. 9L engine and automatic transmission) (AN) Dodge Dakota (with 5.2L engine and manual transmission or 5.9L engine and automatic transmission) (BR/BE)Dodge Ram Pickup (with a 5.2L engine and manual transmission, 5.9L engine and automatic transmission or 8.0L engine) NOTE: This recall applies only to certain vehicles equipped with a California emission control system (sales code NAE) built through April 30, 1998 (MDH 0430XX). Subject The On-Board Diagnostic (OBD) system on about 18,000 of the above vehicles may not detect evaporative emissions purge system malfunctions as required by California Emission Regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update labels and Authorized Modifications labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance PCM Update Previously Performed 08831181 0.2 hours Reprogram Powertrain Control Module 08831182 0.5 hours Add the cost of the labels plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 3450 Not Applicable Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD831". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure The DRB III(R) with either MDS1 or MDS2 is required to perform this repair. ^ If using the MDS1 and DRB III, the MDS must be operating at release 21 or higher and TIL CD release 1184 or higher must be installed. ^ If using the MDS2 and DRB III, the system must be operating at CIS CD2034 or higher. Using the MDS1 1. Connect the MDS1 (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 - CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU screen. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III UPDATE on the DRB III MAIN MENU. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER REPROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS1 AND DRB III on the MDS1, then press NEXT MENU. 7. FOLLOW THE STEPS PRESENTED ON THE MDS1 and DRB III that will allow the DRB III to obtain the current part number of the PCM. 8. The MDS1 will display the part number of the PCM on the vehicle and the appropriate replacement part number(s). Press NEXT MENU to begin programming. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 3451 9. The MDS and DRB III will prompt the operator for any action needed during the remainder of the programming process. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Step C. Using the MDS2 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. B. Install Authorized Software Update Label Fig. 1 Type or print (with a ballpoint pen) the necessary information on the "Authorized Software Update" label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Label Fig. 2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 3452 Type or print (with a ballpoint pen) the necessary information shown in Figure 2 onto the Authorized Modifications Label. Then attach the label near the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Owner Letter EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE Dear DaimlerChrysler Vehicle Owner: DaimlerChrysler has determined that some 1998 Dodge Dakota, Durango, Ram Van/Wagon, Ram Truck, and Jeep(R) Grand Cherokee vehicles, equipped with a V-8 or V-10 engine, may be in violation of California Emissions Regulations. The problem is... The On-Board Diagnostic (OBD) system on your vehicle (identified on the enclosed form) may not detect evaporative emissions purge system malfunctions as required by California Emissions Regulations. As a result, the OBD system on your vehicle may not illuminate the "Check Engine" light if the evaporative emissions purge system malfunctions. This could cause your vehicle to emit hydrocarbon levels above the limits that were established to protect the public health from the dangers of air pollution. Hydrocarbons (unburned fuel) combined with oxides of nitrogen, in the presence of sunlight, can cause the formation of ozone. These pollutants are the primary components of smog. What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will reprogram your vehicle's powertrain control module. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer right away to schedule a service appointment. ^ Bring the enclosed Owner Notification form with you to your dealer. It identifies the required service to the dealer. If you live in California and don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. How the state knows that the recall has been performed... State of California regulations require DaimlerChrysler to provide the Department of Motor Vehicles with a record of all vehicles that have not had the recall service performed. If you live in the state of California and your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. In order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. We are sorry for any inconvenience but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you for your attention to this important matter. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations > Component Locations O/D Solenoid,TCC Solenoid,governor Pressure Sensor,governor Pressure Solenoid Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations > Component Locations > Page 3460 Solenoid Case Connector,park/neutral Position Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations > Page 3461 Transmission Solenoid Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3470 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3476 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 3484 Park/Neutral Position Switch Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3485 Torque Convertor Clutch Solenoid Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Locations > Component Locations O/D Solenoid,TCC Solenoid,governor Pressure Sensor,governor Pressure Solenoid Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Locations > Component Locations > Page 3492 Solenoid Case Connector,park/neutral Position Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Locations > Page 3493 Transmission Solenoid Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3502 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3508 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 3516 Park/Neutral Position Switch Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3517 Torque Convertor Clutch Solenoid Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > 32RE 3-Speed Band: Specifications 32RE 3-Speed SERVICE SPECIFICATIONS Band Adjustment From 72 inch lbs.: Front Band ........................................................................................................................................... ........................................ Back Off 2.25 Turns Rear Band ................................................................. ........................................................................................................................ Back Off 4 Turns TORQUE SPECIFICATIONS Plug, front band reaction ..................................................................................................................... ................................................. 17 Nm (13 ft. lbs.) Locknut, front band adj ........................................ ................................................................................................................................ 34 Nm (25 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > 32RE 3-Speed > Page 3522 Band: Specifications 46RE (A518) 4-Speed SERVICE SPECIFICATIONS Band Adjustment From 72 inch lbs.: Front Band ........................................................................................................................................... ...................................... Back Off 2-7/8 Turns Rear Band .................................................................. ....................................................................................................................... Back Off 2 Turns TORQUE SPECIFICATIONS Plug, front band reaction ..................................................................................................................... ................................................. 17 Nm (13 ft. lbs.) Locknut, front band adj ........................................ ................................................................................................................................ 34 Nm (25 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Page 3523 Band: Adjustments FRONT BAND ADJUSTMENT The front (kickdown) band adjusting screw is located on the left side of the transmission case above the manual valve and throttle valve levers. 1. Raise vehicle. Front Band Adjustment Screw Location 2. Loosen band adjusting screw locknut. Then back locknut off 3-5 turns. Be sure adjusting screw turns freely in case. Apply lubricant to screw threads if necessary. 3. Tighten band adjusting screw to 8 Nm (72 inch lbs.) torque with Inch Pound Torque Wrench C-3380-A, a 3-in. extension and 5/16 socket. Band Adjustment Adapter Tool CAUTION: If Adapter C-3705 is needed to reach the adjusting screw, tighten the screw to only 5 Nm (47-50 inch lbs.) torque. 46RE Transmission Back off front band adjusting screw 2-7/8 turns. - Hold adjuster screw in position and tighten locknut to 41 Nm (30 ft. lbs.) torque. 47RE Transmission Back off front band adjusting screw 1-7/8 turns. - Hold adjuster screw in position and tighten locknut to 43 Nm (30 ft. lbs.) torque. 4. Lower vehicle. REAR BAND ADJUSTMENT The transmission oil pan must be removed for access to the rear band adjusting screw. 1. Raise vehicle. 2. Remove transmission oil pan and drain fluid. 3. Loosen band adjusting screw locknut 5-6 turns. Be sure adjusting screw turns freely in lever. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Page 3524 Rear Band Adjustment Screw Location 4. Tighten adjusting screw to 8 Nm (72 inch lbs.) torque. 46RE Transmission Back off adjusting screw 2 turns. - Hold adjusting screw in place and tighten locknut to 34 Nm (25 ft. lbs.) torque. 47RE Transmission Back off adjusting screw 3 turns. - Hold adjusting screw in place and tighten locknut to 34 Nm (25 ft. lbs.) torque. 5. Position new gasket on oil pan and install pan on transmission. Tighten pan bolts to 17 Nm (13 ft. lbs.) torque. 6. Lower vehicle and refill transmission with MOPAR ATF+4, Type 9602 fluid. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch Clutch: Specifications Direct Clutch Direct Clutch Disc Usage ..................................................................................................................... ........................................................................ 8 Disc Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch > Page 3529 Clutch: Specifications Front Clutch Front Clutch Spring Usage .................................................................................................................. .................................................................... 9 Springs Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch > Page 3530 Clutch: Specifications Overdrive Clutch Overdrive Clutch Disc Usage .............................................................................................................. ....................................................................... 4 Discs Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch > Page 3531 Clutch: Specifications 32RE 3-Speed Clutch Pack Clearance: Front 4-Disc .............................................................................................................................................................. 1.70 - 3.40 mm (0.067 - 0.134 inch) Rear 4-Disc ................................................................................ ............................................................................... 0.81 - 1.40 mm (0.032 - 0.055 inch) Front Clutch Spring Usage .................................................................................................................. ..................................................................... 1 Spring Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch > Page 3532 Clutch: Specifications 46RE (A518) 4-Speed Clutch Pack Clearance: Front 3-Disc .............................................................................................................................................................. 1.78 - 3.28 mm (0.070 - 0.129 inch) Rear 4-Disc ................................................................................ ............................................................................... 0.64 - 1.14 mm (0.025 - 0.045 inch) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3541 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3542 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3548 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3549 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3550 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair Extension Housing: Service and Repair REMOVAL 1. Shift transmission into manual low (1) position. 2. Hoist and support vehicle on safety stands. 3. Mark propeller shaft and axle yoke for alignment reference. Then disconnect and remove shaft. 4. Remove vehicle speed sensor. 5. Remove bolts attaching extension housing to rear support. 6. Using a suitable lifting device, raise transmission off rear mount. 7. Remove rear crossmember. 8. Remove bolts holding extension housing to transmission case. 9. Verify that transmission is in 1 position. Park lock rod is easier to disengage in this position. 10. Remove access plate and gasket from underside of extension housing. Rear Bearing Retaining Ring 11. Using a snap ring plier, spread retaining ring holding rear bearing in extension housing. 12. While spreading retaining ring, pull extension away from transmission case. 13. Separate extension housing from vehicle. INSTALLATION Before installing the extension housing, verify that all gasket sealing surfaces are clean. 1. Position new gasket on housing. Use petroleum jelly to hold gasket in place. 2. Install locating ring in extension housing, if removed. 3. Slide housing onto output shaft. 4. Insert park rod past sprag and slide housing onto shaft unlit the retaining ring contacts the rear bearing. 5. Spread rear bearing retaining ring. 6. Push extension housing forward until fully seated against transmission case. Release locating ring and verify that it is fully seated in rear bearing. 7. Install bolts to hold extension housing to transmission case. Tighten bolts to 43 Nm (32 ft. lbs.) torque. 8. Install gasket and access plate on underside of extension housing. 9. Install rear crossmember. 10. Remove support lift from under transmission. 11. Install bolts to hold extension housing to rear mount. Tighten bolts to 68 Nm (50 ft. lbs.) torque. 12. Install speed sensor. 13. Align and install propeller shaft. 14. Lower vehicle. 15. Top off transmission fluid level if necessary and road test to verify repair. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications > Page 3558 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications > Page 3559 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 32RH ................................................................................................................................................... ................................................. 8.0-8.3L (8.4-8.7 Qt) 46RE ................................................................ ............................................................................................................................. 10.8-11.0L (11.4-11.6 Qt) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3562 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ............................................................................................................ ....................................................... MOPAR ATF +4 Type 9602 or Equivalent Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3563 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications TORQUE SPECIFICATIONS 32/36RH, 46RE Bolt, Fluid Pan ........................................................................................................... ............................................................................... 17 Nm (13 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 3575 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 3581 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > 32RE 3-Speed Fluid Pump: Specifications 32RE 3-Speed SERVICE SPECIFICATIONS Oil Pump Gear Tip Clearance ........................................................................................................................... 0.089 - 0.190 mm (0.0035 - 0.0075 inch) TORQUE SPECIFICATIONS Bolt, oil pump ....................................................................................................................................... ................................................ 20 Nm (15 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > 32RE 3-Speed > Page 3586 Fluid Pump: Specifications 46RE (A518) 4-Speed SERVICE SPECIFICATIONS Oil Pump Gear Tip Clearance ............................................................................................................................... 0.089 - 0.190 mm (0.004 - 0.008 inch) TORQUE SPECIFICATIONS Bolt, Oil Pump ...................................................................................................................................... ................................................ 20 Nm (15 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Governor: > 18-19-98 > Apr > 98 > A/T Engine Bucking/Surging at 5,300 Rpm Governor: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Governor: > 18-19-98 > Apr > 98 > A/T Engine Bucking/Surging at 5,300 Rpm > Page 3595 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Governor: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Governor: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Governor: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 3601 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Page 3602 Governor: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Page 3603 Governor Pressure Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Page 3604 Governor: Service and Repair REMOVAL 1. Hoist and support vehicle on safety stands. 2. Remove transmission fluid pan and filter. 3. Disengage wire connectors from pressure sensor and solenoid. 4. Remove screws holding pressure solenoid retainer to governor body. 5. Separate solenoid retainer from governor. 6. Pull solenoid from governor body. 7. Remove bolts holding governor body to valve body. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Page 3605 8. Separate governor body from valve body. 9. Remove governor body gasket. 10. Remove retainer holding pressure sensor to governor body. 11. Pull pressure sensor from governor body. NOTE: Before installing the pressure sensor and solenoid in the governor body, replace O-ring seals, clean the gasket surfaces and replace gasket. INSTALLATION 1. Lubricate O-ring on pressure sensor with transmission fluid. 2. Align pressure sensor to bore in governor body. 3. Push pressure sensor into governor body. 4. Install retainer to hold pressure sensor to governor body. 5. Place gasket in position on back of governor body. 6. Place governor body in position on valve body. 7. Install bolts to hold governor body to valve body. 8. Lubricate O-ring, on pressure solenoid, with transmission fluid. 9. Align pressure solenoid to bore in governor body. 10. Push solenoid into governor body. 11. Place solenoid retainer in position on governor. 12. Install screws to hold pressure solenoid retainer to governor body. 13. Engage wire connectors into pressure sensor and solenoid. 14. Install transmission fluid pan and (new) filter. 15. Lower vehicle and road test to verify repair. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Input Shaft, A/T > Component Information > Specifications > 32RE 3-Speed Input Shaft: Specifications 32RE 3-Speed Input Shaft End Play ................................................................................................................................................... 0.127 - 1.22 mm (0.005 - 0.048 inch) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Input Shaft, A/T > Component Information > Specifications > 32RE 3-Speed > Page 3610 Input Shaft: Specifications 46RE (A518) 4-Speed Input Shaft End Play ..................................................................................................................................................... 0.86 - 2.13 mm (0.034 - 0.084 inch) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation SYSTEM OPERATION The overdrive-off indicator lamp gives the driver an indication that the automatic transmission overdrive has been locked out. The lamp is controlled by the Powertrain Control Module (PCM) on a hard wired circuit to instrument cluster. The PCM receives an input from the momentary overdrive lockout switch, which is located on the end of the automatic transmission gearshift selector lever. The PCM uses the overdrive lockout switch input, along with numerous other sensor inputs and its internal programming to decide whether the over-drive-off indicator lamp should be on or off. The PCM then turns the lamp on or off by controlling the ground path for the lamp control circuit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 3615 Overdrive Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative overdrive-off indicator lamp condition. If the overdrive-off indicator lamp comes on and stays on with the engine running, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) and the transmission control system circuits. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Unplug the gray PCM wire harness connector. Install a jumper wire between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. Connect the battery negative cable. Turn the ignition switch to the On position. The overdrive-off indicator lamp should light. Remove the jumper wire and the lamp should turn off. If OK, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) and the transmission control system circuits. If not OK, go to Step 5. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the instrument cluster. Check for continuity between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the short circuit as required. 5. Check for continuity between the overdrive lamp driver circuit cavities of the gray PCM wire harness connector and the instrument cluster wire harness connector (connector A). There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Locations > Component Locations O/D Solenoid,TCC Solenoid,governor Pressure Sensor,governor Pressure Solenoid Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Locations > Component Locations > Page 3621 Solenoid Case Connector,park/neutral Position Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Locations > Page 3622 Transmission Solenoid Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation SYSTEM OPERATION The overdrive-off indicator lamp gives the driver an indication that the automatic transmission overdrive has been locked out. The lamp is controlled by the Powertrain Control Module (PCM) on a hard wired circuit to instrument cluster. The PCM receives an input from the momentary overdrive lockout switch, which is located on the end of the automatic transmission gearshift selector lever. The PCM uses the overdrive lockout switch input, along with numerous other sensor inputs and its internal programming to decide whether the over-drive-off indicator lamp should be on or off. The PCM then turns the lamp on or off by controlling the ground path for the lamp control circuit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 3626 Overdrive Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative overdrive-off indicator lamp condition. If the overdrive-off indicator lamp comes on and stays on with the engine running, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) and the transmission control system circuits. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Unplug the gray PCM wire harness connector. Install a jumper wire between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. Connect the battery negative cable. Turn the ignition switch to the On position. The overdrive-off indicator lamp should light. Remove the jumper wire and the lamp should turn off. If OK, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) and the transmission control system circuits. If not OK, go to Step 5. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the instrument cluster. Check for continuity between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the short circuit as required. 5. Check for continuity between the overdrive lamp driver circuit cavities of the gray PCM wire harness connector and the instrument cluster wire harness connector (connector A). There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Specifications > 32RE 3-Speed Planetary Gears: Specifications 32RE 3-Speed Planetary End Play ...................................................................................................................................................... 0.127 - 1.22 mm (0.005 - 0.048 inch) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Specifications > 32RE 3-Speed > Page 3631 Planetary Gears: Specifications 46RE (A518) 4-Speed Planetary End Play ...................................................................................................................................................... 0.150 - 1.22 mm (0.006 - 0.048 inch) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3640 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3646 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3656 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3657 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3663 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3664 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3665 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3669 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3670 Transmission Control Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 32RH 3-Speed Seals and Gaskets: Service and Repair 32RH 3-Speed REMOVAL 1. Raise vehicle. 2. Mark propeller shaft and axle yoke for alignment reference. 3. Disconnect and remove propeller shaft. Removing Extension Housing Yoke Seal 4. Remove old seal with Seal Remover C-3985-B from extension housing. INSTALLATION 1. Place seal in position on extension housing. Installing Extension Housing Yoke Seal 2. Drive seal into extension housing with Seal Installer C-3995-A or C-3972. 3. Carefully guide propeller shaft slip yoke into housing and onto output shaft splines. Align marks made at removal and connect propeller shaft to rear axle pinion yoke. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 32RH 3-Speed > Page 3675 Seals and Gaskets: Service and Repair 46RE (A518) 4-Speed REMOVAL 1. Raise vehicle. 2. Mark propeller shaft and axle yoke for alignment reference. 3. Disconnect and remove propeller shaft. Removing Overdrive Housing Yoke Seal 4. Remove old seal with Seal Remover C-3985-B from overdrive housing. INSTALLATION 1. Place seal in position on overdrive housing. Installing Overdrive Housing Yoke 2. Drive seal into overdrive housing with Seal Installer C-3995-A. 3. Carefully guide propeller shaft slip yoke into housing and onto output shaft splines. Align marks Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 3685 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 3691 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3695 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation TRANSMISSION SPEED SENSOR Transmission Output Speed Sensor The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The rear wheel speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Service and Repair Shift Interlock: Service and Repair REMOVAL AND INSTALLATION The column shift interlock is used to lock the transmission shifter in the Park position when the key is in the Off position. The interlock device is located within the steering column assembly and is not serviceable. If repair is necessary, the steering column assembly must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair Shifter A/T: Service and Repair REMOVAL 1. Remove the upper and lower column shroud. 2. Disconnect the over drive switch harness (if equipped). Gear Shift Lever Mounting Screw 3. Remove the gear shift lever mounting screw and remove the lever. INSTALLATION 1. Install the lever and install the mounting screw and tighten to 20 Nm (177 inch lbs.). 2. Connect the over drive switch harness (if equipped). NOTE: Route and tie off harness to original location. 3. Install the upper and lower column shroud. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 32RE 3-Speed Shift Cable: Adjustments 32RE 3-Speed SHIFT CABLE ADJUSTMENT Check cable adjustment by starting the engine in Park and Neutral. Adjustment is correct if the engine starts only in Park and Neutral. Adjustment is incorrect if the engine starts in any other position, or does not start in either Park or Neutral. If the engine starts in any position other than Park or Neutral, or if the engine will not start at all, the park/neutral position switch may be faulty. Shift Cable Routing Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 32RE 3-Speed > Page 3716 Shift Cable Attachment At Steering Column And Transmission The shift cable is attached to an arm on the steering column and to the transmission shift lever. Brackets support and secure the cable at each end and clips are used to secure the cable to the floor pan. The cable is operated by an arm on the steering column shaft. The cable has a built-in adjuster mechanism at the transmission end. The mechanism consists of an internal clamp and release button that allows the cable to be extended, or shortened for adjustment. SHIFT CABLE ADJUSTMENT CHECK The ignition key should rotate from Off to Lock only when the shift lever is in Park. Shifting out of Park should only be possible when the ignition key is in Off, Run, or Start positions. It should not be possible when the key is in Accessory or Lock position. Engine start should only occur in Park and Neutral position. SHIFT CABLE ADJUSTMENT PROCEDURE 1. Place column shift lever in Park. 2. Raise vehicle. 3. Unsnap cable from transmission shift lever. 4. Move transmission shift lever all the way rearward to Park detent. 5. Release cable adjuster (at transmission end of cable) to unlock cable. 6. Snap cable back onto pin on transmission shift lever. 7. Press cable lock inward to secure cable. 8. Lower vehicle and verify correct cable adjustment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 32RE 3-Speed > Page 3717 Shift Cable: Adjustments 46RE (A518) 4-Speed SHIFT CABLE ADJUSTMENT Check cable adjustment by starting the engine in Park and Neutral. Adjustment is correct if the engine starts only in Park and Neutral. Adjustment is incorrect if the engine starts in any other position, or does not start in either Park or Neutral. If the engine starts in any position other than Park or Neutral, or if the engine will not start at all, the park/neutral position switch may be faulty. Shift Cable Routing Shit Cable Attachemnt At Steering Column And Transmission Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 32RE 3-Speed > Page 3718 The shift cable is attached to an arm on the steering column and to the transmission shift lever. Brackets support and secure the cable at each end and clips are used to secure the cable to the floor pan. The cable is operated by an arm on the steering column shaft. The cable has a built-in adjuster mechanism at the transmission end. The mechanism consists of an internal clamp and release button that allows the cable to be extended, or shortened for adjustment. SHIFT CABLE ADJUSTMENT CHECK The ignition key should rotate from Off to Lock only when the shift lever is in Park. Shifting out of Park should only be possible when the ignition key is in Off, Run, or Start positions. It should not be possible when the key is in Accessory or Lock position. Engine start should only occur in Park and Neutral position. SHIFT CABLE ADJUSTMENT PROCEDURE 1. Place column shift lever in Park. 2. Raise vehicle. 3. Unsnap cable from transmission shift lever. 4. Move transmission shift lever all the way rearward to Park detent. 5. Release cable adjuster (at transmission end of cable) to unlock cable. 6. Snap cable back onto pin on transmission shift lever. 7. Press cable lock inward to secure cable. 8. Lower vehicle and verify correct cable adjust Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > 32RE 3-Speed Throttle Valve Cable/Linkage: Adjustments 32RE 3-Speed TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT Throttle Valve Cable Attachment-At Engine The transmission throttle valve is operated by a cam on the valve body throttle lever. The throttle lever is actuated by a cable connected to the engine throttle body lever. A retaining clip at the engine-end of the cable is removed to provide for cable adjustment. The retaining clip is then installed back onto the throttle valve cable to lock in the adjustment. A correctly adjusted throttle valve cable, will cause the throttle lever on the transmission to move simultaneously with the throttle body lever from the idle position. Proper adjustment allows simultaneous movement without causing the transmission throttle lever to move ahead of, or lag behind the throttle body lever. THROTTLE VALVE CABLE ADJUSTMENT CHECK 1. Turn ignition key to OFF position. 2. Remove air cleaner. 3. Verify that throttle body lever is at curb idle position. Then verify that transmission throttle lever is also at idle (full forward) position. 4. Slide cable off attachment stud on throttle body lever. 5. Compare position of cable end to attachment stud on throttle body lever: a. Cable end and attachment stud should be aligned (or centered on one another) to within 1 mm (0.039 inch) in either direction. b. If cable end and attachment stud are misaligned (off center), cable will have to be adjusted as described in following procedure. 6. Reconnect cable end to attachment stud. Then with aid of a helper, observe movement of transmission throttle lever and lever on throttle body. a. If both levers move simultaneously from idle to half-throttle and back to idle position, adjustment is correct. b. If transmission throttle lever moves ahead of, or lags behind throttle body lever, cable adjustment will be necessary. Or, if throttle body lever prevents transmission lever from returning to closed position, cable adjustment will be necessary. THROTTLE VALVE CABLE ADJUSTMENT PROCEDURE 1. Turn ignition switch to OFF position and shift into Park. 2. Remove air cleaner. 3. Disconnect cable end from attachment stud on throttle body Carefully slide cable off stud. Do not pull or pry cable off. 4. Verify that transmission throttle lever is in idle (full forward) position. Then be sure lever on throttle body is at curb idle position. 5. Insert a small screwdriver under edge of retaining clip and remove retaining clip. 6. Center cable end on attachment stud to within 1 mm (0.039 inch). 7. Install retaining clip onto cable housing. 8. Check cable adjustment. Be sure transmission throttle lever and lever on throttle body move simultaneously and as described in cable adjustment checking procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > 32RE 3-Speed > Page 3723 Throttle Valve Cable/Linkage: Adjustments 46RE (A518) 4-Speed TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT Throttle Valve Cable Attachment-At Engine The transmission throttle valve is operated by a cam on the valve body throttle lever. The throttle lever is actuated by a cable connected to the engine throttle body lever. A retaining clip at the engine-end of the cable is removed to provide for cable adjustment. The retaining clip is then installed back onto the throttle valve cable to lock in the adjustment. A correctly adjusted throttle valve cable, will cause the throttle lever on the transmission to move simultaneously with the throttle body lever from the idle position. Proper adjustment allows simultaneous movement without causing the transmission throttle lever to move ahead of, or lag behind the throttle body lever. THROTTLE VALVE CABLE ADJUSTMENT CHECK 1. Turn ignition key to OFF position. 2. Remove air cleaner. 3. Verify that throttle body lever is at curb idle position. Then verify that transmission throttle lever is also at idle (full forward) position. 4. Slide cable off attachment stud on throttle body lever. 5. Compare position of cable end to attachment stud on throttle body lever: a. Cable end and attachment stud should be aligned (or centered on one another) to within 1 mm (0.039 inch) in either direction. b. If cable end and attachment stud are misaligned-aligned (off center), cable will have to be adjusted as described in following procedure. 6. Reconnect cable end to attachment stud. Then with aid of a helper, observe movement of transmission throttle lever and lever on throttle body a. If both levers move simultaneously from idle to half-throttle and back to idle position,, adjustment is correct. b. If transmission throttle lever moves ahead of, or lags behind throttle body lever, cable adjustment will be necessary. Or, if throttle body lever prevents transmission lever from returning to closed position, cable adjustment will be necessary. THROTTLE VALVE CABLE ADJUSTMENT PROCEDURE 1. Turn ignition switch to OFF position and shift into Park. 2. Remove air cleaner. 3. Disconnect cable end from attachment stud on throttle body. Carefully slide cable off stud. Do not pull or pry cable off. 4. Verify that transmission throttle lever is in idle (full forward) position. Then be sure lever on throttle body is at curb idle position. 5. Insert a small screwdriver under edge of retaining clip and remove retaining clip. 6. Center cable end on attachment stud to within 1 mm (0.039 inch). 7. Install retaining clip onto cable housing 8. Check cable adjustment. Be sure transmission throttle lever and lever on throttle body move simultaneously and as described in cable adjustment checking procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications Bolt, Torque Converter ........................................................................................................................ ..................................................... 31 Nm (23 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 32RH 3-Speed Torque Converter: Service and Repair 32RH 3-Speed REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verity that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. INSTALLATION Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate converter hub and oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. Checking Torque Converter Seating 6. Check converter seating with a scale and straightedge. Surface of converter lugs should be 1/2 inch to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 32RH 3-Speed > Page 3729 Torque Converter: Service and Repair 46RE (A518) 4-Speed REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. INSTALLATION Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate converter hub and oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. Checking Torque Converter Seating 6. Check converter seating with a scale and straightedge. Surface of converter lugs should be 1/2 inch to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 3734 Park/Neutral Position Switch Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3735 Torque Convertor Clutch Solenoid Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3739 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3740 Transmission Control Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures Technical Service Bulletin # 21-06-97A Date: 971219 A/T - Overdrive Unavailable in Cold Temperatures NO: 21-06-97 Rev. A GROUP: Transmission DATE: Dec. 19, 1997 SUBJECT: Overdrive Unavailable in Extreme Cold Temperatures, Bypass Kit Installation, Inhibitor Programming THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-06-97, DATED MAR. 21, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE MARKED WITH **ASTERISKS** AND INCLUDE MODEL CHANGES AND PART NUMBER ADDITIONS FOR V-10 APPLICATIONS. MODELS: 1996 - **1998** (AB) Ram Van/Wagon 1996 (AN) Dakota 1996 - **1998** (BRIBE) Ram Truck 1996 - **1998** (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES AND A 42RE, 44RE, 46RE, OR 47RE TRANSMISSION. SYMPTOM/CONDITION: At ambient temperatures of -20 C (-5 F) or below, the Powertrain Control Module (PCM) will electronically inhibit the transmission from shifting into overdrive. This will protect the transmission from damage if the transmission fluid begins to freeze. In extreme cold climatic regions, this feature can cause customer dissatisfaction due to elimination of overdrive and less than optimal fuel economy. DIAGNOSIS: The cold weather by-pass kit along with disabling the inhibitor feature should only be incorporated for vehicles used in areas of extended cold ambient temperatures. NOTE: THIS KIT WILL DECREASE THE MAXIMUM COOLING CAPACITY OF THE TRANSMISSION'S COOLING SYSTEM. AS A RESULT, IT IS NOT RECOMMENDED THAT THIS BULLETIN BE PERFORMED UNLESS THE ABOVE STATED CONDITION EXISTS. ALSO, IF THE VEHICLE IS USED FOR MODERATE TO HEAVY TOWING IT IS NOT RECOMMENDED. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3749 PARTS/EQUIPMENT REQUIRED: **1 04798668 Kit, By-Pass V-10 Applications** 1 04874284 Kit, Universal By-Pass (See Figure 1 for kit contents) AR(1) 04318044 Thread Sealant 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE ALSO REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3750 WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves installing a cold weather by-pass kit to the transmission cooler circuit, selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes for 1996 models only), and using the DRB III to selectively turn off the overdrive inhibitor feature for all applications. NOTE: IT IS ESSENTIAL THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. NOTE: EVEN WITH BYPASS KIT INSTALLATION AND THE INHIBITOR FEATURE TURNED OFF, 4TH GEAR WILL BE INHIBITED UNTIL THE OIL SUMP TEMPERATURE REACHES 0 C (30 F). THIS MAY TAKE SEVERAL MINUTES. Bypass Kit Installation 1. Record all radio pre-sets and disconnect the negative battery cable. 2. Raise the vehicle for access to the transmission housing. The bypass assembly will be connected to the existing transmission lines and mounted to the transmission housing by means of a bypass adapter. 3. During this installation procedure, some transmission fluid will be lost when the transmission cooler lines are cut (allowing bypass assembly installation). Take proper precautions and check transmission fluid fill level upon completing the installation. 4. It the cold weather bypass kit has provision for an in-line temperature sensor, the threaded "therm-o-well" (in the pressure "P" line of the kit) must be plugged with either the temperature sensor from the existing transmission line or the standard pipe plug provided. Consequently, if the vehicle being serviced is equipped with a temperature sensor (i.e., heavy duty BR truck), remove the temperature sensor from the existing line by un-threading and install it in the "pressure" line provided with the kit. Use Mopar Thread Sealant, p/n 04318044, to ensure a leak free seal. 5. Disconnect the pressure and return lines from the transmission housing fittings. 6. Remove and discard the fittings from the transmission housing. 7. Apply Mopar Thread Sealant, p/n 04318044, to the threaded bypass adapter (# 2 Figure 1). 8. Install the threaded bypass adapter securely into the front pressure port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). 9. Make sure the snap ring and O-ring are properly installed in their respective grooves on the nose of the bypass assembly block. Lubricate the O-ring with ATF. 10. Position the bypass assembly block such that the return port fitting "R" is pointed directly up and the two other fittings are pointed forward. 11. Firmly press the male nose of the bypass assembly into the female body of the threaded bypass adapter until it snaps into place. After snapping into place, the bypass assembly is permanently attached to the adapter. NOTE: THE BYPASS ASSEMBLY CAN ROTATE INSIDE THE ADAPTER, AND REMOVAL OF THE BLOCK FROM THE TRANSMISSION HOUSING (IF REQUIRED) CAN BE ACCOMPLISHED BY UN-THREADING THE ADAPTER. CAUTION: IF FLUSHING THE BYPASS ASSEMBLY IS REQUIRED, IT MUST BE REMOVED FROM THE TRANSMISSION HOUSING AND FORWARD FLUSHED ONLY. FAILING TO REMOVE THE VALVE AND REVERSE FLUSHING WILL RESULT IN TRANSMISSION FAILURE BY PLUGGING THE BYPASS VALVES INTERNAL ORIFICE AND DRAIN BACK VALVE. 12. Apply Mopar Thread Sealant, p/n 04318044, to the threaded end (transmission housing end) of the compression fitting. 13. Install the threaded compression fitting securely into the rear return port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3751 14. Using a small tubing cutter, cut the existing pressure line at approximately 120 mm (5 in.) from the transmission housing end. Repeat the procedure for the existing return line. CAUTION: AFTER CUTTING THE PRESSURE LINE, MARK IT WITH A PIECE OF TAPE FOR IDENTIFICATION. 15. Identify the proper return line ("R" line) by using the marked labels attached to the tubes. 16. Connect the "R" line to the bypass assembly block and the rearward return port of the transmission housing. Tighten the compression fitting finger tight, and then wrench tighten it an additional 1/2 turn. Tighten the inverted flare nut to 6.78 Nm (60 in. lbs.). 17. Select the appropriate "RR" and "P" tubes for the application. Mixing or matching may be required to provide the best routing for your Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3752 application. 18. Loosely connect the pressure line "P" to the pressure port fitting "P" on the bypass assembly block. 19. Loosely connect the radiator return line, "RR" to the "RR" port fitting, on the bypass assembly block. NOTE: DURING THE INSTALLATION OF THE "P" AND "RR" LINES, THE ORDER MAY BE REVERSED TO AID IN THE ASSEMBLY PROCESS. NOTE: ON 5.2L ZJ MODELS, THE THROTTLE VALVE CABLE AND BRACKET MAY REQUIRE REMOVAL FOR BYPASS TUBE CLEARANCE. ONCE THE TUBES ARE INSTALLED LOOSELY, INSTALL THE BRACKET AND THROTTLE VALVE CABLE. MAKE ANY ADJUSTMENTS FOR CLEARANCE AND TIGHTEN THE BYPASS TUBES AND BRACKET ASSEMBLY. 20. Make sure that the existing return line is properly re-attached to the hanger bracket and lay the new return line, "RR", beside it. 21. Install the hose bracket (# 12 in Figure 1) required for the overhead line application. The bracket will replace the existing bracket at the starter mount location. It may require slight modification to provide the best clearance from the exhaust system. 22. Attach clamp (# 11 in Figure 1) and the rubber hose to the "RR" tube to determine the approximate rubber hose routing. For connection to the existing return line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 23. Cut the rubber hose so that it has sufficient length to be attached to the existing return line. 24. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing return line. 25. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 26. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Make modifications as necessary to provide the best routing. 27. Disconnect the "RR" tube from the Bypass Block for access to the "P" port on the block assembly. 28. Attach a clamp and the rubber hose to the "P" tube and determine the approximate rubber hose routing. For connection to the existing pressure line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 29. Cut the rubber hose so that it has sufficient length to be attached to the existing pressure line. 30. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing pressure line. 31. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 32. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Use tie straps and rubber bumpers on the hose to protect the hose from metal surfaces that may cause chaffing. 33. Torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 34. Connect the "RR" ling and torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 35. Re-check to ensure that all connections have been securely tightened and there is sufficient clearance around the exhaust system. 36. If applicable, connect the wire harness to the temperature sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3753 37. Lower the vehicle. 38. Re-connect the negative battery cable and reset the radio stations recorded in step one. 39. Check and adjust the transmission fluid level as outlined in the appropriate Service Manual. 40. Raise the vehicle and check for leaks (idle in Neutral). Flash Programming (1996 Models) NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS UPDATE. THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3754 Programming Cold Overdrive Feature (All Applications) Using the DRB III, use the following procedures to program the overdrive cutoff feature. 1. Connect the DRB III (Scan Tool) to the vehicle and power it up. 2. Use the arrow keys and select # 1 DRB III STANDALONE on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select # 1 1994 - 1998 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU. 4. Use the arrow keys and select # 1 ENGINE on the DRB III SELECT SYSTEM MENU. 5. The module ID screen will appear, press enter to move to next menu. 6. From the SELECT FUNCTION MENU, press the right arrow key for the next page and select # 1 MISCELLANEOUS. 7. From the SELECT MISCELLANEOUS FUNCTION MENU, press the right arrow key for the next page and select # 1 COLD OVERDRIVE FEATURE. 8. Follow the steps presented on the DRB III which will prompt you through the feature selection. 9. When the password is asked for use: 84362172. 10. Follow the remaining prompts for overdrive feature verification. NOTE: IT IS IMPERATIVE THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. Policy/Time Allowance/Failure Code POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-25-17-99-1996 AB/AN/BR/ZJ Models 1.7 Hrs. 21-25-17-99-1997/**1998** AB/BR/BE/ZJ Models 1.5 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures Technical Service Bulletin # 21-06-97A Date: 971219 A/T - Overdrive Unavailable in Cold Temperatures NO: 21-06-97 Rev. A GROUP: Transmission DATE: Dec. 19, 1997 SUBJECT: Overdrive Unavailable in Extreme Cold Temperatures, Bypass Kit Installation, Inhibitor Programming THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-06-97, DATED MAR. 21, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE MARKED WITH **ASTERISKS** AND INCLUDE MODEL CHANGES AND PART NUMBER ADDITIONS FOR V-10 APPLICATIONS. MODELS: 1996 - **1998** (AB) Ram Van/Wagon 1996 (AN) Dakota 1996 - **1998** (BRIBE) Ram Truck 1996 - **1998** (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES AND A 42RE, 44RE, 46RE, OR 47RE TRANSMISSION. SYMPTOM/CONDITION: At ambient temperatures of -20 C (-5 F) or below, the Powertrain Control Module (PCM) will electronically inhibit the transmission from shifting into overdrive. This will protect the transmission from damage if the transmission fluid begins to freeze. In extreme cold climatic regions, this feature can cause customer dissatisfaction due to elimination of overdrive and less than optimal fuel economy. DIAGNOSIS: The cold weather by-pass kit along with disabling the inhibitor feature should only be incorporated for vehicles used in areas of extended cold ambient temperatures. NOTE: THIS KIT WILL DECREASE THE MAXIMUM COOLING CAPACITY OF THE TRANSMISSION'S COOLING SYSTEM. AS A RESULT, IT IS NOT RECOMMENDED THAT THIS BULLETIN BE PERFORMED UNLESS THE ABOVE STATED CONDITION EXISTS. ALSO, IF THE VEHICLE IS USED FOR MODERATE TO HEAVY TOWING IT IS NOT RECOMMENDED. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3760 PARTS/EQUIPMENT REQUIRED: **1 04798668 Kit, By-Pass V-10 Applications** 1 04874284 Kit, Universal By-Pass (See Figure 1 for kit contents) AR(1) 04318044 Thread Sealant 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE ALSO REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3761 WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves installing a cold weather by-pass kit to the transmission cooler circuit, selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes for 1996 models only), and using the DRB III to selectively turn off the overdrive inhibitor feature for all applications. NOTE: IT IS ESSENTIAL THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. NOTE: EVEN WITH BYPASS KIT INSTALLATION AND THE INHIBITOR FEATURE TURNED OFF, 4TH GEAR WILL BE INHIBITED UNTIL THE OIL SUMP TEMPERATURE REACHES 0 C (30 F). THIS MAY TAKE SEVERAL MINUTES. Bypass Kit Installation 1. Record all radio pre-sets and disconnect the negative battery cable. 2. Raise the vehicle for access to the transmission housing. The bypass assembly will be connected to the existing transmission lines and mounted to the transmission housing by means of a bypass adapter. 3. During this installation procedure, some transmission fluid will be lost when the transmission cooler lines are cut (allowing bypass assembly installation). Take proper precautions and check transmission fluid fill level upon completing the installation. 4. It the cold weather bypass kit has provision for an in-line temperature sensor, the threaded "therm-o-well" (in the pressure "P" line of the kit) must be plugged with either the temperature sensor from the existing transmission line or the standard pipe plug provided. Consequently, if the vehicle being serviced is equipped with a temperature sensor (i.e., heavy duty BR truck), remove the temperature sensor from the existing line by un-threading and install it in the "pressure" line provided with the kit. Use Mopar Thread Sealant, p/n 04318044, to ensure a leak free seal. 5. Disconnect the pressure and return lines from the transmission housing fittings. 6. Remove and discard the fittings from the transmission housing. 7. Apply Mopar Thread Sealant, p/n 04318044, to the threaded bypass adapter (# 2 Figure 1). 8. Install the threaded bypass adapter securely into the front pressure port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). 9. Make sure the snap ring and O-ring are properly installed in their respective grooves on the nose of the bypass assembly block. Lubricate the O-ring with ATF. 10. Position the bypass assembly block such that the return port fitting "R" is pointed directly up and the two other fittings are pointed forward. 11. Firmly press the male nose of the bypass assembly into the female body of the threaded bypass adapter until it snaps into place. After snapping into place, the bypass assembly is permanently attached to the adapter. NOTE: THE BYPASS ASSEMBLY CAN ROTATE INSIDE THE ADAPTER, AND REMOVAL OF THE BLOCK FROM THE TRANSMISSION HOUSING (IF REQUIRED) CAN BE ACCOMPLISHED BY UN-THREADING THE ADAPTER. CAUTION: IF FLUSHING THE BYPASS ASSEMBLY IS REQUIRED, IT MUST BE REMOVED FROM THE TRANSMISSION HOUSING AND FORWARD FLUSHED ONLY. FAILING TO REMOVE THE VALVE AND REVERSE FLUSHING WILL RESULT IN TRANSMISSION FAILURE BY PLUGGING THE BYPASS VALVES INTERNAL ORIFICE AND DRAIN BACK VALVE. 12. Apply Mopar Thread Sealant, p/n 04318044, to the threaded end (transmission housing end) of the compression fitting. 13. Install the threaded compression fitting securely into the rear return port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3762 14. Using a small tubing cutter, cut the existing pressure line at approximately 120 mm (5 in.) from the transmission housing end. Repeat the procedure for the existing return line. CAUTION: AFTER CUTTING THE PRESSURE LINE, MARK IT WITH A PIECE OF TAPE FOR IDENTIFICATION. 15. Identify the proper return line ("R" line) by using the marked labels attached to the tubes. 16. Connect the "R" line to the bypass assembly block and the rearward return port of the transmission housing. Tighten the compression fitting finger tight, and then wrench tighten it an additional 1/2 turn. Tighten the inverted flare nut to 6.78 Nm (60 in. lbs.). 17. Select the appropriate "RR" and "P" tubes for the application. Mixing or matching may be required to provide the best routing for your Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3763 application. 18. Loosely connect the pressure line "P" to the pressure port fitting "P" on the bypass assembly block. 19. Loosely connect the radiator return line, "RR" to the "RR" port fitting, on the bypass assembly block. NOTE: DURING THE INSTALLATION OF THE "P" AND "RR" LINES, THE ORDER MAY BE REVERSED TO AID IN THE ASSEMBLY PROCESS. NOTE: ON 5.2L ZJ MODELS, THE THROTTLE VALVE CABLE AND BRACKET MAY REQUIRE REMOVAL FOR BYPASS TUBE CLEARANCE. ONCE THE TUBES ARE INSTALLED LOOSELY, INSTALL THE BRACKET AND THROTTLE VALVE CABLE. MAKE ANY ADJUSTMENTS FOR CLEARANCE AND TIGHTEN THE BYPASS TUBES AND BRACKET ASSEMBLY. 20. Make sure that the existing return line is properly re-attached to the hanger bracket and lay the new return line, "RR", beside it. 21. Install the hose bracket (# 12 in Figure 1) required for the overhead line application. The bracket will replace the existing bracket at the starter mount location. It may require slight modification to provide the best clearance from the exhaust system. 22. Attach clamp (# 11 in Figure 1) and the rubber hose to the "RR" tube to determine the approximate rubber hose routing. For connection to the existing return line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 23. Cut the rubber hose so that it has sufficient length to be attached to the existing return line. 24. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing return line. 25. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 26. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Make modifications as necessary to provide the best routing. 27. Disconnect the "RR" tube from the Bypass Block for access to the "P" port on the block assembly. 28. Attach a clamp and the rubber hose to the "P" tube and determine the approximate rubber hose routing. For connection to the existing pressure line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 29. Cut the rubber hose so that it has sufficient length to be attached to the existing pressure line. 30. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing pressure line. 31. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 32. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Use tie straps and rubber bumpers on the hose to protect the hose from metal surfaces that may cause chaffing. 33. Torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 34. Connect the "RR" ling and torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 35. Re-check to ensure that all connections have been securely tightened and there is sufficient clearance around the exhaust system. 36. If applicable, connect the wire harness to the temperature sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3764 37. Lower the vehicle. 38. Re-connect the negative battery cable and reset the radio stations recorded in step one. 39. Check and adjust the transmission fluid level as outlined in the appropriate Service Manual. 40. Raise the vehicle and check for leaks (idle in Neutral). Flash Programming (1996 Models) NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS UPDATE. THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3765 Programming Cold Overdrive Feature (All Applications) Using the DRB III, use the following procedures to program the overdrive cutoff feature. 1. Connect the DRB III (Scan Tool) to the vehicle and power it up. 2. Use the arrow keys and select # 1 DRB III STANDALONE on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select # 1 1994 - 1998 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU. 4. Use the arrow keys and select # 1 ENGINE on the DRB III SELECT SYSTEM MENU. 5. The module ID screen will appear, press enter to move to next menu. 6. From the SELECT FUNCTION MENU, press the right arrow key for the next page and select # 1 MISCELLANEOUS. 7. From the SELECT MISCELLANEOUS FUNCTION MENU, press the right arrow key for the next page and select # 1 COLD OVERDRIVE FEATURE. 8. Follow the steps presented on the DRB III which will prompt you through the feature selection. 9. When the password is asked for use: 84362172. 10. Follow the remaining prompts for overdrive feature verification. NOTE: IT IS IMPERATIVE THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. Policy/Time Allowance/Failure Code POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-25-17-99-1996 AB/AN/BR/ZJ Models 1.7 Hrs. 21-25-17-99-1997/**1998** AB/BR/BE/ZJ Models 1.5 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 3766 Transmission Cooler: Description and Operation AUTOMATIC TRANSMISSION OIL COOLER Top View Of Transmission Oil Cooling Circuit Automatic Transmission Oil Cooler Lines The automatic transmission oil is cooled when it passes through a cooler in the radiator lower tank. In case of a leak in the transmission oil cooler, engine coolant may become mixed with transmission fluid. Transmission fluid may also have entered the engine cooling system. Both cooling system and transmission should be drained and inspected in the event cooler is leaking. TRANSMISSION AUXILIARY COOLER Transmission Auxiliary Cooler Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 3767 Auxiliary transmission coolers are mounted ahead of the radiator. They operate in conjunction with the main cooler located in the radiator lower tank. The transmission oil is routed through the main cooler in the radiator lower tank first, then the auxiliary cooler before returning to the transmission. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 3768 Transmission Cooler: Service and Repair Remove radiator. The servicing should be performed by a qualified repair facility. Once the repaired or replacement radiator has been installed, fill the cooling system and inspect for leaks. If the transmission operates properly after repairing the leak, drain the transmission and torque converter while hot. Remove the transmission oil pan and inspect sludge and/or rust. Inspect for a dirty or plugged inlet filter. If none of these conditions are found, the transmission may not require reconditioning. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications Transmission Mount: Specifications Insulator Bracket to Transmission (Rear) Bolts 50 ft.lb Insulator to Transmission Bracket (Rear) Through Bolt/Nut 50 ft.lb Insulator to Rear Support Nuts 30 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 3772 Transmission Mount: Service and Repair REMOVAL 1. Raise vehicle on a hoist. 2. Position transmission jack and raise rear of transmission and engine SLIGHTLY. 3. Remove rear mount through-bolt and nut. 4. Remove U-shaped bracket from the frame crossmember. Remove the insulator from the U-shaped bracket. Rear Support 5. Remove rear engine support from the bottom face of transmission extension housing. INSTALLATION 1. Attach the rear engine support to the bottom face of transmission extension housing. Tighten the bolts to 68 Nm (50 ft. lbs.) torque. 2. Install insulator on the U-shaped bracket. Tighten the nuts to 41 Nm (30 ft. lbs.) torque. 3. Install the through-bolt through the insulator and U-bracket assembly and the rear engine support. Tighten the through-bolt nut to 68 Nm (50 ft. lbs.) torque. 4. Attach the U-shaped bracket to the crossmember. Tighten the attaching bolts to 41 Nm (30 ft. lbs.) torque. 5. Remove the transmission jack. 6. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3776 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation TRANSMISSION SPEED SENSOR Transmission Output Speed Sensor The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The rear wheel speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations Transmission Solenoids Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Adjustments > 32RE 3-Speed Valve Body: Adjustments 32RE 3-Speed CONTROL PRESSURE ADJUSTMENTS There are two control pressure adjustments on the valve body; Line Pressure - Throttle Pressure Line and throttle pressures are interdependent because each affects shift quality and timing. As a result, both adjustments must be performed properly and in the correct sequence. Adjust line pressure first and throttle pressure last. LINE PRESSURE ADJUSTMENT Line Pressure Adjustment Measure distance from the valve body to the inner edge of the adjusting screw with an accurate steel scale. Distance should be 33.4 mm (1-5/16 inch). If adjustment is required, turn the adjusting screw in, or out, to obtain required distance setting. NOTE: The 33.4 mm (1-5/16 inch) setting is an approximate setting. Manufacturing tolerances may make it necessary to vary from this dimension to obtain desired pressure. One complete turn of the adjusting screw changes line pressure approximately 1-2/3 psi (9 kPa). Turning the adjusting screw counterclockwise increases pressure while turning the screw clockwise decreases pressure. THROTTLE PRESSURE ADJUSTMENT Throttle Pressure Adjustment Insert Gauge Tool C-3763 between the throttle lever cam and the kickdown valve stem. Push the gauge tool inward to compress the kickdown valve against the spring and bottom the throttle valve. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Adjustments > 32RE 3-Speed > Page 3791 Maintain pressure against kickdown valve spring. Turn throttle lever stop screw until the screw head touches throttle lever tang and the throttle lever cam touches gauge tool. NOTE: The kickdown valve spring must be fully compressed and the kickdown valve completely bottomed to obtain correct adjustment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Adjustments > 32RE 3-Speed > Page 3792 Valve Body: Adjustments 46RE (A518) 4-Speed CONTROL PRESSURE ADJUSTMENTS There are two control pressure adjustments on the valve body; Line Pressure - Throttle Pressure Line and throttle pressures are interdependent because each affects shift quality and timing. As a result, both adjustments must be performed properly and in the correct sequence. Adjust line pressure first and throttle pressure last. LINE PRESSURE ADJUSTMENT Line Pressure Adjustment Measure distance from the valve body to the inner edge of the adjusting screw with an accurate steel scale. Distance should be 33.4 min (1-5/16 inch). If adjustment is required, turn the adjusting screw in, or out, to obtain required distance setting. NOTE: The 33.4 mm (1-5/16 inch) setting is an approximate setting. Manufacturing tolerances may make it necessary to vary from this dimension to obtain desired pressure. One complete turn of the adjusting screw changes line pressure approximately 1-2/3 psi (9 kPa). Turning the adjusting screw counterclockwise increases pressure while turning the screw clockwise decreases pressure. THROTTLE PRESSURE ADJUSTMENT Throttle Pressure Adjustment Insert Gauge Tool C-3763 between the throttle lever cam and the kickdown valve stem. Push the gauge tool inward to compress the kickdown valve against the spring and bottom the throttle valve. Maintain pressure against kickdown valve spring. Turn throttle lever stop screw until the screw head touches throttle lever tang and the throttle lever Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Adjustments > 32RE 3-Speed > Page 3793 cam touches gauge tool. NOTE: The kickdown valve spring must be fully compressed and the kickdown valve completely bottomed to obtain correct adjustment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation Valve Body: Service and Repair Removal and Installation 32RH 3-Speed The valve body can be disassembled for cleaning and inspection of the individual components. Refer to Disassembly and Assembly for proper procedures. The only replaceable valve body components are: Manual lever. - Manual lever washer, seal, E-clip, and shaft seal. - Manual lever detent ball. - Throttle lever. - Fluid filter. - Switch valve, spring, and pressure adjusting screw bracket. - Converter clutch solenoid. - Park rod and E-clip. The remaining valve body components are serviced only as part of a complete valve body assembly. REMOVAL 1. Shift transmission into NEUTRAL. 2. Raise vehicle. 3. Remove gearshift and throttle levers from shaft of valve body manual lever. 4. Position drain pan under transmission oil pan. 5. Remove transmission oil pan and gasket. 6. Remove fluid filter from valve body. 7. Disconnect lock-up solenoid wire, if necessary. 8. Remove bolts attaching valve body to transmission case. Accumulator Piston And Springs 9. Lower valve body enough to remove accumulator piston and springs. 10. Work manual lever shaft out of transmission case. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3796 Valve Body 11. Lower valve body, rotate valve body away from case, pull park rod out of sprag, and remove valve body. INSTALLATION Manual Lever Shaft Seal 1. Check condition of manual lever shaft seal in transmission case. Replace seal if lip is cut or worn. Install new seal with 15/16 deep well socket. 2. Check condition of seals on accumulator piston. Install new piston seals, if necessary. 3. Place valve body manual lever in low (1 position) so ball on park lock rod will be easier to install in sprag. 4. Lubricate shaft of manual lever with petroleum jelly. This will ease inserting shaft through seal in case. 5. Position valve body in case and work end of park lock rod into and through pawl sprag. Turn propeller shaft to align sprag and park lock teeth if necessary. The rod will click as it enters pawl. Move rod to check engagement. CAUTION: It is possible for the park rod to displace into a cavity just above the pawl sprag during installation. Make sure the rod is actually engaged in the pawl and has not displaced into this cavity. 6. Install accumulator springs and piston into case. Then swing valve body over piston and outer spring to hold it in place. 7. Align accumulator piston and outer spring and manual lever shaft in case. 8. Then seat valve body in case and install one or two bolts to hold valve body in place. 9. Tighten valve body bolts alternately and evenly to 11 Nm (100 inch lbs.) torque. 10. Connect lock-up solenoid wire, if necessary. 11. Install new fluid filter on valve body. Tighten filter screws to 4 Nm (35 inch lbs.) torque. 12. Install throttle and gearshift levers on valve body manual lever shaft. 13. Check and adjust front and rear bands if necessary. 14. Install oil pan and new gasket. Tighten pan bolts to 17 Nm (13 ft. lbs.) torque. 15. Lower vehicle and fill transmission with Mopar8 ATF+4, type 9602 fluid. 16. Check and adjust gearshift and throttle valve cables, if necessary. 46RE (A518) 4-Speed VALVE BODY The valve body can be removed for service without having to remove the transmission assembly. The valve body can be disassembled for cleaning and inspection of the individual components. Refer to Disassembly and Assembly section for proper procedures. The only replaceable valve body components are: Manual lever. - Manual lever washer, seal, E-clip, and shaft seal. - Manual lever detent ball. - Throttle lever. - Fluid filter. - Pressure adjusting screw bracket. - Governor pressure solenoid. - Governor pressure sensor. - Converter clutch/overdrive solenoid assembly and harness (includes sump temperature thermistor). - Governor housing gasket. - Solenoid case connector O-rings. The remaining valve body components are serviced only as part of a complete valve body assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3797 REMOVAL 1. Shift transmission into NEUTRAL. 2. Raise vehicle. 3. Remove gearshift and throttle levers from shaft of valve body manual lever. Transmission Case Connector 4. Disconnect wires at solenoid case connector. 5. Position drain pan under transmission oil pan. 6. Remove transmission oil pan and gasket. 7. Remove fluid filter from valve body. 8. Remove bolts attaching valve body to transmission case. 9. Lower valve body enough to remove accumulator piston and springs. 10. Work manual lever shaft and electrical connector out of transmission case. Valve Body 11. Lower valve body, rotate valve body away from case, pull park rod out of sprag, and remove valve body. INSTALLATION Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3798 Valve Body Harness Connector O-Ring Seal 1. Check condition of O-ring seals on valve body harness connector. Replace seals on connector body if cut or worn. Manual Lever Shaft Seal 2. Check condition of manual lever shaft seal in transmission case. Replace seal if lip is cut or worn. Install new seal with 15/16 deep well socket. Accumulator Piston Components 3. Check condition of seals on accumulator piston. Install new piston seals, if necessary. 4. Place valve body manual lever in low (1 position) so ball on park lock rod will be easier to install in sprag. 5. Lubricate shaft of manual lever with petroleum jelly. This will ease inserting shaft through seal in case. 6. Lubricate seal rings on valve body harness connector with petroleum jelly. 7. Position valve body in case and work end of park lock rod into and through pawl sprag. Turn propeller shaft to align sprag and park lock teeth if necessary. The rod will click as it enters pawl. Move rod to check engagement. CAUTION: It is possible for the park rod to displace into a cavity just above the pawl sprag during installation. Make sure the rod is actually engaged in the pawl and has not displaced into this cavity. 8. Install accumulator springs and piston into case. Then swing valve body over piston and outer spring to hold it in place. 9. Align accumulator piston and outer spring, manual lever shaft and electrical connector in case. 10. Then seat valve body in case and install one or two bolts to hold valve body in place. 11. Tighten valve body bolts alternately and evenly to 11 Nm (100 inch lbs.) torque. 12. Install new fluid filter on valve body. Tighten filter screws to 4 Nm (35 inch lbs.) torque. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3799 13. Install throttle and gearshift levers on valve body manual lever shaft. 14. Check and adjust front and rear bands if necessary. 15. Connect solenoid case connector wires. 16. Install oil pan and new gasket. Tighten pan bolts to 17 Nm (13 ft. lbs.) torque. 17. Lower vehicle and fill transmission with MOPAR(r) ATF+4, type 9602 fluid. 18. Check and adjust gearshift and throttle valve cables, if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3800 Valve Body: Service and Repair Disassembly Lower Housing Disassembly 1. Remove timing valve cover. 2. Remove 3-4 timing valve and spring. 3. Remove 3-4 quick fill valve, spring and plug. 4. Remove 3-4 shift valve and spring. Lower Housing Shift Valves And Springs 5. Remove converter clutch valve, spring and plug. 6. Remove converter clutch timing valve, retainer and valve spring. Main Component Body CAUTION: Do not clamp any valve body component in a vise. This practice can damage the component resulting in unsatisfactory operation after assembly and installation. Do not use pliers to remove any of the valves, plugs or springs and do not force any of the components out or into place. The valves and valve body housings will be damaged if force is used. Tag or mark the valve body springs for reference as they are removed. Do not allow them to become intermixed. 1. Remove fluid filter. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3801 Governor Pressure Solenoid And Sensor Wire Locations 2. Disconnect wires from governor pressure sensor and solenoid. Governor Body And Retainer Plate Attaching Screw 3. Remove screws attaching governor body and retainer plate to transfer plate. Governor Body And Gasket 4. Remove retainer plate, governor body and gasket from transfer plate. 5. Disconnect wires from governor pressure sensor, if not done previously. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3802 Governor Pressure Sensor 6. Remove governor pressure sensor from governor body. Sensor is retained in body with M-shaped spring clip. Remove clip with small pointed tool and slide sensor out of body. Governor Pressure Solenoid 7. Remove governor pressure solenoid by pulling it straight out of bore in governor body. Remove and discard solenoid O-rings if worn, cut, or torn. 8. Remove transmission fluid filter. Solenoid Harness Case Connector Shoulder Bolt 9. Remove small shoulder bolt that secures solenoid harness case connector to 3-4 accumulator housing. Retain shoulder bolt. Either tape it to harness or thread it back into accumulator housing after connector removal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3803 Unhooking Solenoid Harness From Accumulator Cover Plate 10. Unhook overdrive/converter solenoid harness from 3-4 accumulator cover plate. Solenoid Assembly Screws 11. Turn valve body over and remove screws that attach overdrive/converter solenoid assembly to valve body. Solenoid Assembly 12. Remove solenoid and harness assembly from valve body. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3804 Boost Valve Cover Location 13. Remove boost valve cover. Boost Valve Components 14. Remove boost valve retainer, valve spring and boost valve. Detent Ball And Spring 15. Secure detent ball and spring with Retainer Tool 6583. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3805 Park Rod 16. Remove park rod E-clip and separate rod from manual lever. Throttle Lever E-Clip And Washer 17. Remove E-clip and washer that retains throttle lever shaft in manual lever. Manual And Throttle Lever 18. Remove manual lever and throttle lever. Rotate and lift manual lever off valve body and throttle lever shaft. Then slide throttle lever out of valve body. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3806 Detent Ball And Spring 19. Position pencil magnet next to detent housing to catch detent ball and spring. Then carefully remove Retainer Tool 6583 and remove detent ball and spring. Adjusting Screw Bracket Fastener 20. Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate. Hold bracket firmly against spring tension while removing last screw. Adjusting Screw Bracket And Spring 21. Remove adjusting screw bracket, line pressure adjusting screw, pressure regulator valve spring and switch valve spring. Do not remove throttle pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during removal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3807 Upper Housing Control Valve Locations 22. Turn upper housing over and remove switch valve, regulator valve and spring, and manual valve. 23. Remove kickdown detent, kickdown valve, and throttle valve and spring. Accumulator Housing Screw Locations 24. Loosen left-side 3-4 accumulator housing attaching screw about 2-3 threads. Then remove center and right-side housing attaching screws. Shift And Converter Clutch Valve Springs And Plug 25. Carefully rotate 3-4 accumulator housing upward and remove 3-4 shift valve spring and converter clutch valve plug and spring. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3808 Accumulator Housing, Valve Springs And Plug 26. Remove left-side screw and remove 3-4 accumulator housing from valve body. Boost Valve Tube Brace 27. Bend back tabs on boost valve tube brace. Boost Valve Tube 28. Remove boost valve connecting tube. Disengage tube from upper housing port first. Then rock opposite end of tube back and forth to work it out of lower housing. CAUTION: Do not use tools to loosen or pry the connecting tube out of the valve body housings. Loosen and remove the tube by hand only. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3809 Lower Housing 29. Turn valve body over so lower housing is facing upward. In this position, the two check balls in upper housing will remain in place and not fall out when lower housing and separator plate are removed. 30. Remove screws attaching valve body lower housing to upper housing and transfer plate. Note position of boost valve tube brace for assembly reference. 31. Remove lower housing and overdrive separator plate from transfer plate. ECE Check Ball 32. Remove the ECE check ball from the transfer plate. The ECE check ball is approximately 4.8 mm (3/16 inch) in diameter. Transfer Plate 33. Remove transfer plate from upper housing. 34. Turn transfer plate over so upper housing separator plate is facing upward. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3810 Upperhousing Separator Plate 35. Remove upper housing separator plate from transfer plate. Note position of filter in separator plate for assembly reference. Rear Clutch And Rear Servo Check Ball Locations 36. Remove rear clutch and rear servo check balls from transfer plate. Note check ball location for assembly reference. Upper Housing Disassembly Check Ball Locations In Upper Housing 1. Note location of check balls in valve body upper housing. Then remove the one large diameter and the six smaller diameter check balls. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3811 Shuttle Valve E-Clip And Secondary Spring Location 2. Remove governor plug and shuttle valve covers. Shuttle And Boost Valve Components 3. Remove E-clip that secures shuttle valve secondary spring on valve stem. 4. Remove throttle plug, primary spring, shuttle valve, secondary spring, and spring guides. 5. Remove boost valve retainer, spring and valve if not previously removed. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3812 Upper Housing Control Valve Locations 6. Remove throttle plug and 1-2 and 2-3 governor plugs. Upper Housing Shift Valve And Pressure Plug Locations 7. Turn upper housing around and remove limit valve and shift valve covers. 8. Remove limit valve housing. Then remove retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 9. Remove 1-2 shift control valve and spring. 10. Remove 1-2 shift valve and spring. 11. Remove 2-3 shift valve and spring from valve body. 12. Remove pressure plug cover. 13. Remove line pressure plug, sleeve, throttle pressure plug and spring. 3-4 Accumulator 1. Remove end plate from housing. 2. Remove piston spring. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3813 Accumulator Housing Components 3. Remove piston. Remove and discard piston seals. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3814 Valve Body: Service and Repair Disassembly and Assembly 32RH 3-Speed DISASSEMBLY Valve Body Assembly CAUTION: Do not clamp any part of the valve body assembly in a vise. This practice will distort the valve body and transfer plate resulting in valve bind. Slide valves and plugs out carefully. Do not use force at any time. The valves and valve body will be damaged if force is used. Also tag or mark the valve body springs for reference as they are removed. Do not allow them to become intermixed. 1. Remove screws attaching adjusting screw bracket to valve body and transfer plate. Hold bracket firmly against spring force while removing last screw. Adjusting Screw Bracket And Spring Removal 2. Remove adjusting screw bracket, line pressure adjusting screw, pressure regulator spring and switch valve spring. Do not remove throttle pressure adjusting screw from bracket and do not disturb adjusting screw settings during removal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3815 Securing Detent Ball And Spring With Retainer Tool 3. Secure detent ball and spring in housing with retainer tool 6583. Removing Manual And Throttle Levers 4. Remove manual shaft E-clip and washer. 5. Pull manual shaft and park rod assembly upward out of valve body and off throttle lever. 6. Remove Retainer Tool 6583. Then remove and retain detent ball and spring. 7. Remove throttle lever. Clutch Module And Connecting Tube Removal/Installation 8. Remove park rod E-clip and separate rod from manual lever. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3816 9. Remove screws attaching converter clutch module to valve body and remove module and connecting tube. Valve Body-To-Transfer Plate Screw Locations 10. Turn valve body over so transfer plate is facing upward. With valve body in this position, valve body check balls will remain in place and not fall out when transfer plate is removed. 11. Remove screws attaching transfer plate to valve body. Transfer Plate Removal/Installation 12. Remove transfer plate and separator plate from valve body. Note position of filter and clutch solenoid for reference. Remove valve body check balls. Note that check balls may be steel or plastic. 13. Position transfer plate on bench so separator plate, filter and lockup solenoid are facing up. This will avoid having rear clutch and rear servo check balls fall out when plates are separated. 14. Remove screws attaching separator plate to transfer plate. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3817 Converter Clutch Solenoid Removal 15. Remove converter clutch solenoid from separator plate. Transfer And Separator Plates 16. Note position of filter, solenoid and rear clutch/rear servo check balls for assembly reference. Clutch and servo check balls may be steel or plastic. Shuttle Valve E-Clip And Secondary Spring Location 17. Remove shuttle valve end plate. 18. Remove shuttle valve E-clip and remove secondary spring and spring guides from end of valve. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3818 Control Valves And Governor Plugs 19. Remove governor valve end plate. 20. Remove switch valve and pressure regulator valve from valve body. 21. Remove throttle valve and spring, kickdown valve and detent and manual valve from valve body. 22. Remove 1-2 and 2-3 shift valve governor plugs from valve body. 23. Remove shuttle valve throttle plug, primary spring and shuttle valve from valve body. 24. Remove 1-2 shift control valve and spring from valve body. 25. Remove 2-3 shift valve and spring from valve body. 26. Remove 1-2 shift valve and spring from valve body. 27. Remove regulator valve end plate. 28. Remove regulator valve line pressure plug, pressure plug sleeve, throttle pressure plug and spring. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3819 ASSEMBLY CAUTION: Do not force valves or plugs into place during reassembly. If the valve body bores, valves and plugs are free of distortion or burrs, the valve body components should all slide into place easily. In addition, do not overtighten the transfer plate and valve body screws during reassembly. Overtightening can distort the valve body resulting in valve sticking, cross leakage and unsatisfactory operation. Tighten valve body screws to recommended torque only. 1. Lubricate valve body bores, valves and plugs with MOPAR(r) ATF+4, type 9602, transmission fluid. Valve Body Components Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3820 2. Insert rear clutch and rear servo check balls in transfer plate. 3. Install filter screen in separator plate. 4. Align and install separator plate on transfer plate. Verify check ball position before installing separator plate on transfer plate. Installing Converter Cluch Solenoid-32RH 5. Install new O-ring on converter clutch solenoid and insert solenoid in separator plate. Then secure solenoid in position with attaching screw. Tighten screw to 4 Nm 35 inch lbs.) torque. Correct Position Of Valve Body Check Balls 6. Position valve body so internal passages and check ball seats are facing upward. Then install check balls in valve body. There are a total of seven check balls; The one large check ball is approximately 11/32 inch in diameter. The remaining check balls are approximately 1/4 inch in diameter. 7. Align and install assembled transfer and separator plates on valve body. Install and tighten valve body screws alternately in a diagonal pattern to 4 Nm (35 inch lbs.) torque. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3821 Converter Clutch Module Components 8. Assemble and install lockup module and components on valve body. 9. Assemble regulator valve line pressure plug, sleeve, throttle plug and spring. insert assembly in valve body and install end plate. Tighten end plate screws to 4 Nm (35 inch lbs.) torque. 10. Install 1-2 and 2-3 shift valves and springs. 11. Install 1-2 shift control valve and spring. 12. Install shuttle valve as follows: a. Insert shuttle valve in bore. b. Insert plastic guides in shuttle valve secondary spring. c. Install spring on end of valve. d. Hold shuttle valve in place. Then compress secondary spring and install E-clip in groove at end of valve. e. Verify that spring and E-clip are properly seated before proceeding. 13. Install shuttle valve cover plate. Tighten end plate screws to 4 Nm (35 inch lbs.) torque. 14. Install 1-2 and 2-3 valve governor plugs in valve body. Then install shuttle valve primary spring and throttle plug. 15. Align and install governor plug end plate on valve body and install end plate screws. Tighten screws to 4 Nm (35 inch lbs.) torque. 16. Install manual valve. 17. Install throttle valve and spring. Then install kickdown valve and detent. 18. Install pressure regulator valve and switch valve in valve body. Park Rod Install 19. Install manual lever detent spring in housing. Place detent ball on end of spring and push ball and spring into housing. Secure ball and spring with Detent Retainer 6583. 20. Insert line pressure adjusting screw in adjusting screw bracket. 21. Install spring on end of line pressure regulator valve. 22. Install switch valve spring on tang at end of adjusting screw bracket. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3822 23. Position adjusting screw bracket on valve body. Align valve springs and press bracket into place. Install short, upper bracket screws first and long bottom screw last. Verify that valve springs and bracket are properly aligned. Then tighten all three bracket screws to 4 Nm (35 inch lbs.) torque. 24. Install module and connecting tube. Be sure long end of tube goes to module. Tighten module screws to 4 Nm (35 inch lbs.) torque. 25. Install throttle lever in valve body. Then install manual lever over throttle lever and start manual lever into valve body. 26. Align manual lever detent with detent ball and align lever arm with manual valve. Hold throttle lever upward. Then press down on manual lever until lever is fully seated. 27. Install manual lever seal, washer and retaining E-clip. 28. Lubricate shaft of manual lever with light coat of petroleum jelly. This will help protect seal lip when manual shaft seal is installed. Manual And Throttle Lever Alignment 29. Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve. 30. If line pressure and/or throttle pressure adjustment screw settings were not disturbed, continue with overhaul or reassembly. However, if adjustment screw settings were moved or changed, re-adjust as described in Valve Body Control Pressure Adjustment procedure. 46RE (A518) 4-Speed DISASSEMBLY CAUTION: Do not clamp any valve body, component in a vise. This practice can damage the component resulting in unsatisfactory operation after assembly and installation. Do not use pliers to remove any of the valves, plugs or springs and do not force any of the components out or into place. The valves and valve body housings will be damaged if force is used. Tag or mark the valve body springs for reference as they are removed. Do not allow them to become intermixed. 1. Remove fluid filter. Governor Pressure Solenoid And Sensor Wire Locations 2. Disconnect wires from governor pressure sensor and solenoid. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3823 Governor Body And Retainer Plate Attaching Screw 3. Remove screws attaching governor body and retainer plate to transfer plate. Governor Body And Gasket 4. Remove retainer plate, governor body and gasket from transfer plate. 5. Disconnect wires from governor pressure sensor, if not done previously. Governor Pressure Sensor 6. Remove governor pressure sensor from governor body. Sensor is retained in body with M-shaped spring clip. Remove clip with small pointed tool and slide sensor out of body. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3824 Governor Pressure Solenoid 7. Remove governor pressure solenoid by pulling it straight out of bore in governor body. Remove and discard solenoid O-rings if worn, cut, or torn. 8. Remove transmission fluid filter. Solenoid Harness Case Connector Shoulder Bolt 9. Remove small shoulder bolt that secures solenoid harness case connector to 3-4 accumulator housing. Retain shoulder bolt. Either tape it to harness or thread it back into accumulator housing after connector removal. Unhooking Solenoid Harness From Accumulator Cover Plate 10. Unhook overdrive/converter solenoid harness from 3-4 accumulator cover plate. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3825 Solenoid Assembly Screws 11. Turn valve body over and remove screws that attach overdrive/converter solenoid assembly to valve body. Solenoid Assembly 12. Remove solenoid and harness assembly from valve body. Boost Valve Cover Location 13. Remove boost valve cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3826 Boost Valve Components 14. Remove boost valve retainer, valve spring and boost valve. Detent Ball And Spring 15. Secure detent ball and spring with Retainer Tool 6583. Park Rod 16. Remove park rod E-clip and separate rod from manual lever. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3827 Throttle Lever E-Clip And Washer 17. Remove E-clip and washer that retains throttle lever shaft in manual lever. Manual And Throttle Lever 18. Remove manual lever and throttle lever. Rotate and lift manual lever off valve body and throttle lever shaft. Then slide throttle lever out of valve body. Detent Ball And Spring 19. Position pencil magnet next to detent housing to catch detent ball and spring. Then carefully remove Retainer Tool 6583 and remove detent ball and spring. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3828 Adjusting Screw Bracket Fastener 20. Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate. Hold bracket firmly against spring tension while removing last screw. Adjusting Screw Bracket And Spring 21. Remove adjusting screw bracket, line pressure adjusting screw, pressure regulator valve spring and switch valve spring. Do not remove throttle pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during removal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3829 Upper Housing Control Valve Locations 22. Turn upper housing over and remove switch valve, regulator valve and spring, and manual valve. 23. Remove kickdown detent, kickdown valve, and throttle valve and spring. Accumulator Housing Screw Locations 24. Loosen left-side 3-4 accumulator housing attaching screw about 2-3 threads. Then remove center and right-side housing attaching screws. Shift And Converter Clutch Valve Springs And Plug 25. Carefully rotate 3-4 accumulator housing upward and remove 3-4 shift valve spring and converter clutch valve plug and spring. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3830 Accumulator Housing, Valve Springs And Plug 26. Remove left-side screw and remove 3-4 accumulator housing from valve body. Boost Valve Tube Brace 27. Bend back tabs on boost valve tube brace. Boost Valve Tube 28. Remove boost valve connecting tube. Disengage tube from upper housing port first. Then rock opposite end of tube back and forth to work it out of lower housing. CAUTION: Do not use tools to loosen or pry the connecting tube out of the valve body housings. Loosen and remove the tube by hand only. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3831 Lower Housing 29. Turn valve body over so lower housing is facing upward. In this position, the two check balls in upper housing will remain in place and not fall out when lower housing and separator plate are removed. 30. Remove screws attaching valve body lower housing to upper housing and transfer plate. Note position of boost valve tube brace for assembly reference. 31. Remove lower housing and overdrive separator plate from transfer plate. ECE Check Ball 32. Remove the ECE check ball from the transfer plate. The ECE check ball is approximately 4.8 mm (3/16 inch) in diameter. Transfer Plate 33. Remove transfer plate from upper housing. 34. Turn transfer plate over so upper housing separator plate is facing upward. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3832 Upper Housing Separator Plate 35. Remove upper housing separator plate from transfer plate. Note position of filter in separator plate for assembly reference. Rear Clutch And Rear Servo Check Ball Locations 36. Remove rear clutch and rear servo check balls from transfer plate. Note check ball location for assembly reference. VALVE BODY UPPER HOUSING Check Ball Locations In Upper Housing 1. Note location of check balls in valve body upper housing. Then remove the one large diameter and the six smaller diameter check balls. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3833 Shuttle Valve E-Clip And Secondary Spring Location 2. Remove governor plug and shuttle valve covers. Shuttle And Boost Valve Components 3. Remove E-clip that secures shuttle valve secondary spring on valve stem. 4. Remove throttle plug, primary spring, shuttle valve, secondary spring, and spring guides. 5. Remove boost valve retainer, spring and valve if not previously removed. 6. Remove throttle plug and 1-2 and 2-3 governor plugs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3834 Upper Housing Shift Valve And Pressure Plug Locations 7. Turn upper housing around and remove limit valve and shift valve covers. 8. Remove limit valve housing. Then remove retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 9. Remove 1-2 shift control valve and spring. 10. Remove 1-2 shift valve and spring. 11. Remove 2-3 shift valve and spring from valve body. 12. Remove pressure plug cover. 13. Remove line pressure plug, sleeve, throttle pressure plug and spring. VALVE BODY LOWER HOUSING 1. Remove timing valve cover. 2. Remove 3-4 timing valve and spring. 3. Remove 3-4 quick fill valve, spring and plug. 4. Remove 3-4 shift valve and spring. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3835 Lower Housing Shift Valves And Springs 5. Remove converter clutch valve, spring and plug. 6. Remove converter clutch timing valve, retainer and valve spring. 3-4 ACCUMULATOR HOUSING 1. Remove end plate from housing. 2. Remove piston spring. Accumulator Housing Components 3. Remove piston. Remove and discard piston seals. ASSEMBLY CAUTION: Do not force valves or plugs into place during reassembly. If the valve body bores, valves and plugs are free of distortion or burrs, the valve body components should all slide into place easily. In addition, do not overtighten the transfer plate and valve body screws during reassembly. Overtightening can distort the housings resulting in valve sticking, cross leakage and unsatisfactory operation. Tighten valve body screws to Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3836 recommended torque only. LOWER HOUSING 1. Lubricate valves, springs, and the housing valve and plug bores with clean transmission fluid. 2. Install 3-4 timing valve spring and valve in lower housing. 3. Install 3-4 quick fill valve in lower housing. 4. Install 3-4 quick fill valve spring and plug in housing. 5. Install timing valve end plate. Tighten end plate screws to 4 Nm (35 inch lbs.) torque. 3-4 ACCUMULATOR 1. Lubricate accumulator piston, seals and housing piston bore with clean transmission fluid. 2. Install new seal rings on accumulator piston. 3. Install piston and spring in housing. 4. Install end plate on housing. TRANSFER PLATE Rear Clutch And Rear Servo Check Ball Locations 1. Install rear clutch and rear servo check balls in transfer plate. Separator Plate Filter Screen Installation 2. Install filter screen in upper housing separator plate. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3837 Brace Plate 3. Align and position upper housing separator plate on transfer plate. 4. Install brace plate. Tighten brace attaching screws to 4 Nm (35 inch lbs.) torque. 5. Install remaining separator plate attaching screws. Tighten screws to 4 Nm (35 inch lbs.) torque. UPPER AND LOWER HOUSING Check Ball Locations In Upper Housing 1. Position upper housing so internal passages and check ball seats are facing upward. Then install check balls in housing. Eight check balls are used. The single large check ball is approximately 8.7 mm (11/32 inch) diameter. The single small check ball is approximately 4.8 mm (3/16 inch) in diameter. The remaining 6 check balls are approximately 6.3 mm (1/4 inch) in diameter. Installing Transfer Plate On Upper Housing Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3838 2. Position assembled transfer plate and upper housing separator plate on upper housing. Be sure filter screen is seated in proper housing recess. 3. Install the ECE check ball into the transfer plate. The ECE check ball is approximately 4.8 mm (3/16 inch) in diameter. Lower Housing Separator Plate 4. Position lower housing separator plate on transfer plate. Shuttle And Boost Valve Components 5. Install lower housing on assembled transfer plate and upper housing. 6. Install and start all valve body screws by hand except for the screws to hold the boost valve tube brace. Save those screws for later installation. Then tighten screws evenly to 4 Nm (35 inch lbs.) torque. Start at center and work out to sides when tightening screws. UPPER HOUSING VALVE AND PLUG Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3839 Installing Lower Housing On Transfer Plate And Upper Housing Upper Housing Control Valve Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3840 Refer to images to perform the following steps: 1. Lubricate valves, plugs, springs with clean transmission fluid. 2. Assemble regulator valve line pressure plug, sleeve, throttle plug and spring. Insert assembly in upper housing and install cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 3. Install 1-2 and 2-3 shift valves and springs. 4. Install 1-2 shift control valve and spring. 5. Install retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 6. Install limit valve housing and cover plate. Tighten screws to 4 Nm (35 inch lbs.). 7. Install shuttle valve as follows: a. Insert plastic guides in shuttle valve secondary spring and install spring on end of valve. b. Install shuttle valve into housing. c. Hold shuttle valve in place. d. Compress secondary spring and install E-clip in groove at end of shuttle valve. e. Verify that spring and E-clip are properly seated before proceeding. 8. Install shuttle valve cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 9. Install 1-2 and 2-3 valve governor plugs in valve body. 10. Install shuttle valve primary spring and throttle plug. 11. Align and install governor plug cover. Tighten cover screws to 4 Nm (35 inch lbs.) torque. BOOST VALVE TUBE AND BRACE Boost Valve Tube 1. Position valve body assembly so lower housing is facing upward. 2. Lubricate tube ends and housing ports with transmission fluid or petroleum jelly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3841 3. Start tube in lower housing port first. Then swing tube downward and work opposite end of tube into upper housing port. 4. Insert and seat each end of tube in housings. Boost Valve Tube And Brace 5. Slide tube brace under tube and into alignment with valve body screw holes. 6. Install and finger tighten three screws that secure tube brace to valve body housings. Securing Boost Valve Tube With Brace Tabs 7. Bend tube brace tabs up and against tube to hold it in position. 8. Tighten all valve body housing screws to 4 Nm (35 inch lbs.) torque after tube and brace are installed. Tighten screws in diagonal pattern starting at center and working outward. 3-4 ACCUMULATOR Converter Clutch And 3-4 Shift Valve Springs Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3842 1. Position converter clutch valve and 3-4 shift valve springs in housing. 2. Loosely attach accumulator housing with rightside screw. Install only one screw at this time as accumulator must be free to pivot upward for ease of installation. 3. Install 3-4 shift valve and spring. 4. Install converter clutch timing valve and spring. 5. Position plug on end of converter clutch valve spring. Then compress and hold springs and plug in place with fingers of one hand. 6. Swing accumulator housing upward over valve springs and plug. Seating 3-4 Accumulator On Lower Housing 7. Hold accumulator housing firmly in place and install remaining two attaching screws. Be sure springs and clutch valve plug are properly seated. Tighten screws to 4 Nm (35 inch lbs.). VALVE BODY FINAL 1. Install boost valve, valve spring, retainer and cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 2. Insert manual lever detent spring in upper housing. Detent Ball Spring 3. Position detent ball on end of spring. Then hold detent ball and spring in detent housing with Retainer Tool 6583. 4. Install throttle lever in upper housing. Then install manual lever over throttle lever and start manual lever into housing. 5. Align manual lever with detent ball and manual valve. Hold throttle lever upward. Then press down on manual lever until fully seated. Remove detent ball retainer tool after lever is seated. 6. Then install manual lever seal, washer and E-clip. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3843 Manual And Throttle Lever Alignment 7. Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve. 8. Position line pressure adjusting screw in adjusting screw bracket. 9. Install spring on end of line pressure regulator valve. 10. Install switch valve spring on tang at end of adjusting screw bracket. 11. Install manual valve. 12. Install throttle valve and spring. 13. Install kickdown valve and detent. 14. Install pressure regulator valve. 15. Install switch valve. 16. Position adjusting screw bracket on valve body. Align valve springs and press bracket into place. Install short, upper bracket screws first and long bottom screw last. Verify that valve springs and bracket are properly aligned. Then tighten all three bracket screws to 4 Nm (35 inch lbs.) torque. 17. Lubricate solenoid case connector O-rings and shaft of manual lever with light coat of petroleum jelly. 18. Obtain new fluid filter for valve body but do not install filter at this time. 19. If line pressure and/or throttle pressure adjustment screw settings were not disturbed, continue with overhaul or reassembly. However, if adjustment screw settings were moved or changed, readjust as described in Valve Body Control Pressure Adjustment procedure. Solenoid Harness Case Connector Shoulder Bolt 20. Attach solenoid case connector to 3-4 accumulator with shoulder-type screw. Connector has small locating tang that fits in dimple at top of accumulator housing. Seat tang in dimple before tightening connector screw. 21. Install solenoid assembly and gasket. Tighten solenoid attaching screws to 8 Nm (72 inch lbs.) torque. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3844 Solenoid Harness Routing 22. Verify that solenoid wire harness is properly routed. Solenoid harness must be clear of manual lever and park rod and not be pinched between accumulator housing and cover. GOVERNOR BODY, SENSOR AND SOLENOID 1. Turn valve body assembly over so accumulator side of transfer plate is facing down. Governor Pressure Sensor 2. Install new O-rings on governor pressure solenoid and sensor. 3. Lubricate solenoid and sensor O-rings with clean transmission fluid. 4. Install governor pressure sensor in governor body. Then secure sensor with M-shaped retaining clip. Governor Pressure Solenoid 5. Install governor pressure solenoid in governor body. Push solenoid in until it snaps into place in body. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3845 Governor Body And Gasket 6. Position governor body gasket on transfer plate. Pressure Solenoid Retainer 7. Install retainer plate on governor body and around solenoid. Be sure solenoid connector is positioned in retainer cutout. 8. Align screw holes in governor body and transfer plate. Then install and tighten governor body screws to 4 Nm (35 inch lbs.) torque. Governor Pressure Sensor And Solenoid Connectors 9. Connect harness wires to governor pressure solenoid and governor pressure sensor. 10. Perform Line Pressure and Throttle Pressure adjustments, refer to adjustment section of this group for proper procedures. 11. Install fluid filter and pan. 12. Lower vehicle. 13. Fill transmission with recommended fluid and road test vehicle to verify repair. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3846 Valve Body: Service and Repair Cleaning and Inspection Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Do not immerse any of the electrical components in cleaning solution. Clean the governor solenoid and sensor and the dual solenoid and harness assembly by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. Wipe the governor pressure sensor and solenoid valve with dry, lint free shop towels only. The O-rings on the sensor and solenoid valve are the only serviceable components. Be sure the vent ports in the solenoid valve are open and not blocked by dirt or debris. Replace the valve and/or sensor only when DRB scan tool diagnosis indicates this is necessary. Or, if either part has sustained physical damage (dented, deformed, broken, etc.). CAUTION: Do not turn the small screw at the end of the solenoid valve for any reason. Turning the screw in either direction will ruin solenoid calibration and result in solenoid failure. In addition, the filter on the solenoid valve is NOT serviceable. Do not try to remove the filter as this will damage the valve housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3847 Upper Housing Valves, Plugs, Springs And Brackets Inspect the throttle and manual valve levers and shafts. Do not attempt to straighten a bent shaft or correct a loose lever. Replace these components if worn, bent, loose or damaged in any way. Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3848 CAUTION: Many of the valves and plugs, such as the throttle valve, shuttle valve plug, 1-2 shift valve and 1-2 governor plug, are made of coated aluminum. Aluminum components are identified by the dark color of the special coating applied to the surface (or by testing with a magnet). Do not sand aluminum valves or plugs under any circumstances. This practice could damage the special coating causing the valves/plugs to stick and bind. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Check the two separator plates for distortion or damage of any kind. Inspect the upper housing, lower housing, 3-4 accumulator housing, and transfer plate carefully. Be sure all fluid passages are clean and clear. Check condition of the upper housing and transfer plate check balls as well. The check balls and ball seats must not be worn or damaged. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. The only serviceable valve body components are listed below. The remaining valve body components are serviced only as part of a complete valve body assembly. Serviceable parts are: - dual solenoid and harness assembly - solenoid gasket - solenoid case connector O-rings and shoulder bolt - switch valve and spring - pressure adjusting screw and bracket assembly - throttle lever - manual lever and shaft seal - throttle lever shaft seal, washer, and E-clip - fluid filter and screws - detent ball and spring - valve body screws - governor pressure solenoid - governor pressure sensor and retaining clip - park lock rod and E-clip Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3849 Valve Body: Service and Repair Assembly Assembly Precaution CAUTION: Do not force valves or plugs into place during reassembly. If the valve body bores, valves and plugs are free of distortion or burrs, the valve body components should all slide into place easily. In addition, do not overtighten the transfer plate and valve body screws during reassembly. Overtightening can distort the housings resulting in valve sticking, cross leakage and unsatisfactory operation. Tighten valve body screws to recommended torque only. NOTE: Follow assembly steps in order shown for proper valve body assembly. Boost Valve and Brace Assembly Boost Valve Tube 1. Position valve body assembly so lower housing is facing upward. 2. Lubricate tube ends and housing ports with transmission fluid or petroleum jelly. 3. Start tube in lower housing port first. Then swing tube downward and work opposite end of tube into upper housing port. 4. Insert and seat each end of tube in housings. Boost Valve Tube And Brace 5. Slide tube brace under tube and into alignment with valve body screw holes. 6. Install and finger tighten three screws that secure tube brace to valve body housings. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3850 Securing Boost Valve Tube With Brace Tabs 7. Bend tube brace tabs up and against tube to hold it in position. 8. Tighten all valve body housing screws to 4 Nm (35 inch lbs.) torque after tube and brace are installed. Tighten screws in diagonal pattern starting at center and working outward. Governor Body, Sensor and Solenoid Assembly 1. Turn valve body assembly over so accumulator side of transfer plate is facing down. Governor Pressure Sensor 2. Install new O-rings on governor pressure solenoid and sensor. 3. Lubricate solenoid and sensor O-rings with clean transmission fluid. 4. Install governor pressure sensor in governor body. Then secure sensor with M-shaped retaining clip. Governor Pressure Solenoid 5. Install governor pressure solenoid in governor body. Push solenoid in until it snaps into place in body. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3851 Governor Body And Gasket 6. Position governor body gasket on transfer plate. Pressure Solenoid Retainer 7. Install retainer plate on governor body and around solenoid. Be sure solenoid connector is positioned in retainer cutout. 8. Align screw holes in governor body and transfer plate. Then install and tighten governor body screws to 4 Nm (35 inch lbs.) torque. Governor Pressure Sensor And Solenoid Connectors 9. Connect harness wires to governor pressure solenoid and governor pressure sensor. 10. Perform Line Pressure and Throttle Pressure adjustments, refer to adjustment section for proper procedures. 11. Install fluid filter and pan. 12. Lower vehicle. 13. Fill transmission with recommended fluid and road test vehicle to verify repair. Lower Housing Disassembly Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3852 Lower Housing Shift Valves And Springs 1. Lubricate valves, springs, and the housing valve and plug bores with clean transmission fluid. 2. Install 3-4 timing valve spring and valve in lower housing. 3. Install 3-4 quick fill valve in lower housing. 4. Install 3-4 quick fill valve spring and plug in housing. 5. Install timing valve end plate. Tighten end plate screws to 4 Nm (35 inch lbs.) torque. Transfer Plate Assembly Rear Clutch And Rear Servo Sheck Ball Locations 1. Install rear clutch and rear servo check balls in transfer plate. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3853 Seperator Plate Filter Screen Installation 2. Install filter screen in upper housing separator plate. Brace Plate 3. Align and position upper housing separator plate on transfer plate. 4. Install brace plate. Tighten brace attaching screws to 4 Nm (35 inch lbs.) torque. 5. Install remaining separator plate attaching screws. Tighten screws to 4 Nm (35 inch lbs.) torque. Upper and Lower Housing Assembly Check Ball Locations In Upper Housing 1. Position upper housing so internal passages and check ball seats are facing upward. Then install check balls in housing. Eight check balls are used. The single large check ball is approximately 8.7 mm (11/32 inch) diameter. The single small check ball is approximately 4.8 mm (3/16 inch) in diameter. The remaining 6 check balls are approximately 6.3 mm (1/4 inch) in diameter. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3854 Installing Transfer Plate On Upper Housing 2. Position assembled transfer plate and upper housing separator plate on upper housing. Be sure filter screen is seated in proper housing recess. ECE Check Ball 3. Install the ECE check ball into the transfer plate. The ECE check ball is approximately 4.8 mm (3/16 inch) in diameter. Lower Housing Separator Plate 4. Position lower housing separator plate on transfer plate. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3855 Installing Lower Housing On Transfer Plate And Upper Housing 5. Install lower housing on assembled transfer plate and upper housing. 6. Install and start all valve body screws by hand except for the screws to hold the boost valve tube brace. Save those screws for later installation. Then tighten screws evenly to 4 Nm (35 inch lbs.) torque. Start at center and work out to sides when tightening screws. Upper Housing Valve and Plug Assembly Shuttle And Boost Valve Components Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3856 Upper Housing Control Valve Locations Upper Housing Shift Valve And Pressure Plug Locations Refer to figures to perform the following steps. 1. Lubricate valves, plugs, springs with clean transmission fluid. 2. Assemble regulator valve line pressure plug, sleeve, throttle plug and spring. Insert assembly in upper housing and install cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 3. Install 1-2 and 2-3 shift valves and springs. 4. Install 1-2 shift control valve and spring. 5. Install retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 6. Install limit valve housing and cover plate. Tighten screws to 4 Nm (35 inch lbs.). 7. Install shuttle valve as follows: a. Insert plastic guides in shuttle valve secondary spring and install spring on end of valve. b. Install shuttle valve into housing. c. Hold shuttle valve in place. d. Compress secondary spring and install E-clip in groove at end of shuttle valve. e. Verify that spring and E-clip are properly seated before proceeding. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3857 8. Install shuttle valve cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 9. Install 1-2 and 2-3 valve governor plugs in valve body. 10. Install shuttle valve primary spring and throttle plug. 11. Align and install governor plug cover. Tighten cover screws to 4 Nm (35 inch lbs.) torque. Valve Body Final Assembly and Adjustment 1. Install boost valve, valve spring, retainer and cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 2. Insert manual lever detent spring in upper housing. Detent Ball Spring 3. Position detent ball on end of spring. Then hold detent ball and spring in detent housing with Retainer Tool 6583. 4. Install throttle lever in upper housing. Then install manual lever over throttle lever and start manual lever into housing. 5. Align manual lever with detent ball and manual valve. Hold throttle lever upward. Then press down on manual lever until fully seated. Remove detent ball retainer tool after lever is seated. 6. Then install manual lever seal, washer and E-clip. Manual And Throttle Lever Alignment 7. Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve. 8. Position line pressure adjusting screw in adjusting screw bracket. 9. Install spring on end of line pressure regulator valve. 10. Install switch valve spring on tang at end of adjusting screw bracket. 11. Install manual valve. 12. Install throttle valve and spring. 13. Install kickdown valve and detent. 14. Install pressure regulator valve. 15. Install switch valve. 16. Position adjusting screw bracket on valve body. Align valve springs and press bracket into place. Install short, upper bracket screws first and long bottom screw last. Verify that valve springs and bracket are properly aligned. Then tighten all three bracket screws to 4 Nm (35 inch lbs.) torque. 17. Lubricate solenoid case connector O-rings and shaft of manual lever with light coat of petroleum jelly. 18. Obtain new fluid filter for valve body but do not install filter at this time. 19. If line pressure and/or throttle pressure adjustment screw settings were not disturbed, continue with overhaul or reassembly. However, if adjustment screw settings were moved or changed, readjust as described in Valve Body Control Pressure Adjustment procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3858 Solenoid Harness Case Connector Shoulder Bolt 20. Attach solenoid case connector to 3-4 accumulator with shoulder-type screw. Connector has small locating tang that fits in dimple at top of accumulator housing. Seat tang in dimple before tightening connector screw. 21. Install solenoid assembly and gasket. Tighten solenoid attaching screws to 8 Nm (72 inch lbs.) torque. Solenoid Harness Routing 22. Verify that solenoid wire harness is properly routed. Solenoid harness must be clear of manual lever and park rod and not be pinched between accumulator housing and cover. 3-4 Accumulator Assembly Installation Converter Clutch And 3-4 Shift Valve Springs 1. Position converter clutch valve and 3-4 shift valve springs in housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3859 2. Loosely attach accumulator housing with right-side screw. Install only one screw at this time as accumulator must be free to pivot upward for ease of installation. 3. Install 3-4 shift valve and spring. 4. Install converter clutch timing valve and spring. 5. Position plug on end of converter clutch valve spring. Then compress and hold springs and plug in place with fingers of one hand. 6. Swing accumulator housing upward over valve springs and plug. Seating 3-4 Accumulator On Lower Housing 7. Hold accumulator housing firmly in place and install remaining two attaching screws. Be sure springs and clutch valve plug are properly seated. Tighten screws to 4 Nm (35 inch lbs.). 3-4 Accumulator Reassembly Accumulator Housing Components 1. Lubricate accumulator piston, seals and housing piston bore with clean transmission fluid. 2. Install new seal rings on accumulator piston. 3. Install piston and spring in housing. 4. Install end plate on housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Specifications Carrier Bearings: Specifications Differential: Bearing Preload ................................................................................................................................... ............................................ 0.38 mm (0.015 inch) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Adjustments > Rear Axle - 8 1/4 and 9 1/4 Carrier Bearings: Adjustments Rear Axle - 8 1/4 and 9 1/4 DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH The following must be considered when adjusting bearing pre-load and gear backlash: The maximum ring gear backlash variation is 0.003 inch (0.076 mm). - Mark the gears so the same teeth are meshed during all backlash measurements. - Maintain the torque while adjusting the bearing pre-load and ring gear backlash. - Excessive adjuster torque will introduce a high bearing load and cause premature bearing failure. Insufficient adjuster torque can result in excessive differential case free-play and ring gear noise. - Insufficient adjuster torque will not support the ring gear correctly and can cause excessive differential case free-play and ring gear noise. NOTE: The differential bearing cups will not always immediately follow the threaded adjusters as they are moved during adjustment. To ensure accurate bearing cup responses to the adjustments: Maintain the gear teeth engaged (meshed) as marked. - The bearings must be seated by rapidly rotating the pinion gear a half turn back and forth. - Do this five to ten times each time the threaded adjusters are adjusted. Threaded Adjuster Tool 1. Use Wrench C-4164 to adjust each threaded adjuster inward until the differential bearing freeplay is eliminated. Allow some ring gear backlash (approximately 0.01 inch/0.25 mm) between the ring and pinion gear. Seat the bearing cups with the procedure described above. Ring Gear Backlash Measurement 2. Install dial indicator and position the plunger against the drive side of a ring gear tooth. Measure the backlash at 4 positions (90° apart) around the ring gear. Locate and mark the area of minimum backlash. 3. Rotate the ring gear to the position of the least backlash. Mark the gear so that all future backlash measurements will be taken with the same gear teeth meshed. 4. Loosen the right-side, tighten the left-side threaded adjuster. Obtain backlash of 0.003 to 0.004 inch (0.076 to 0.102 mm) with each adjuster tightened to 14 Nm (10 ft. lbs.). Seat the bearing cups with the procedure described above. 5. Tighten the differential bearing cap bolts; 8 1/4 axles: 95 Nm (70 ft. lbs.) - 9 1/4 axles: 136 Nm (100 ft. lbs.) 6. Tighten the right-side threaded adjuster to 102 Nm (75 ft. lbs.). Seat the bearing cups with the procedure described above. Continue to tighten the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Adjustments > Rear Axle - 8 1/4 and 9 1/4 > Page 3867 right-side adjuster and seat bearing cups until the torque remains constant at 102 Nm (75 ft. lbs.) 7. Measure the ring gear backlash. The range of backlash is 0.006 to 0.008 inch (0.15 to 0.203 mm). 8. Continue increasing the torque at the rightside threaded adjuster until the specified backlash is obtained. NOTE: The left-side threaded adjuster torque should have approximately 102 Nm (75 ft. lbs.). If the torque is considerably less, the complete adjustment procedure must be repeated. 9. Tighten the left-side threaded adjuster until 102 Nm (75 ft. lbs.) torque is indicated. Seat the bearing rollers with the procedure described above. Do this until the torque remains constant. 10. Install the threaded adjuster locks and tighten the lock screws to 10 Nm (90 inch lbs.). After the proper backlash is achieved, perform the Gear Contact Analysis procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Adjustments > Rear Axle - 8 1/4 and 9 1/4 > Page 3868 Carrier Bearings: Adjustments Rear Axle - 248RBI INTRODUCTION Axle Adjustment Shim Locations-248 RBI Differential side bearing pre-load and gear backlash is achieved by selective shims positioned behind the differential side bearing cones. The proper shim thickness can be determined using slip-fit dummy bearings D-343 in place of the differential side bearings and a dial indicator C-3339. Before proceeding with the differential bearing pre-load and gear backlash measurements, measure the pinion gear depth and prepare the pinion gear for installation. Establishing proper pinion gear depth is essential to establishing gear backlash and tooth contact patterns. After the overall shim thickness to take up differential side play is measured, the pinion gear is installed, and the gear backlash shim thickness is measured. The overall shim thickness is the total of the dial indicator reading and the pre-load specification added together. The gear backlash measurement determines the thickness of the shim used on the ring gear side of the differential case. Subtract the gear backlash shim thickness from the total overall shim thickness and select that amount for the pinion gear side of the differential. Differential shim measurements are performed with axle spreader W-129-B removed. SHIM SELECTION NOTE: It is difficult to salvage the differential side bearings during the removal procedure. Install replacement bearings if necessary. 1. Remove differential side bearings from differential case. 2. Remove factory installed shims from differential case. 3. Install ring gear on differential case and tighten bolts to specification, if necessary. 4. Install dummy side bearings D-343 on differential case. 5. Install differential case in axle housing. Tighten Bolts Holding Bearing Caps 6. Install the marked bearing caps in their correct positions. Install and snug the bolts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Adjustments > Rear Axle - 8 1/4 and 9 1/4 > Page 3869 Seat Pinion Gear Side Differential Dummy Side Bearing Seat Ring Gear Side Differential Dummy Side Bearing 7. Using a dead-blow type mallet, seat the differential dummy bearings to each side of the axle housing. Differential Side Play Measurement 8. Thread guide stud C-3288-B into rear cover bolt hole below ring gear. 9. Attach a dial indicator C-3339 to guide stud. Position the dial indicator plunger on a flat surface between the ring gear bolt heads. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Adjustments > Rear Axle - 8 1/4 and 9 1/4 > Page 3870 Hold Differential Case And Zero Dial Indicator 10. Push and hold differential case to pinion gear side of axle housing. 11. Zero dial indicator face to pointer. Hold Differential Case And Read Dial Indicator 12. Push and hold differential case to ring gear side of the axle housing. 13. Record dial indicator reading. 14. Add 0.015 in. (0.38 mm) to the zero end play total. This new total represents the thickness of shims to compress, or pre-load the new bearings when the differential is installed. 15. Rotate dial indicator out of the way on the guide stud. 16. Remove differential case and dummy bearings from axle housing. 17. Install the pinion gear in axle housing. Install the pinion yoke, or flange, and establish the correct pinion rotating torque. 18. Install differential case and dummy bearings D-343 in axle housing (without shims), install bearing caps and tighten bolts snug. 19. Seat ring gear side dummy bearing. 20. Position the dial indicator plunger on a flat surface between the ring gear bolt heads. 21. Push and hold differential case toward pinion gear. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Adjustments > Rear Axle - 8 1/4 and 9 1/4 > Page 3871 Hold Differential Case And Zero Dial Indicator 22. Zero dial indicator face to pointer. Hold Differential Case And Read Dial Indicator 23. Push and hold differential case to ring gear side of the axle housing. 24. Record dial indicator reading. 25. This is the thickness shim required on the ring gear side of the differential case to achieve proper backlash. 26. Subtract the backlash shim thickness from the total pre-load shim thickness. The remainder is the shim thickness required on the pinion side of the axle housing. 27. Rotate dial indicator out of the way on guide stud. 28. Remove differential case and dummy bearings from axle housing. 29. Install side bearing shims on differential case hubs. 30. Install side bearings and cups on differential case. 31. Install spreader W-129-B on axle housing and spread axle opening enough to receive differential case. 32. Install differential case in axle housing. 33. Remove spreader from axle housing. 34. Rotate the differential case several times to seat the side bearings. Ring Gear Backlash Measurement 35. Position the indicator plunger against a ring gear tooth. 36. Push and hold ring gear upward while not allowing the pinion gear to rotate. 37. Zero dial indicator face to pointer. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Adjustments > Rear Axle - 8 1/4 and 9 1/4 > Page 3872 Backlash Shim Adjustment 38. Push and hold ring gear downward while not allowing the pinion gear to rotate. Dial indicator reading should be between 0.12 mm (0.005 inch) and 0.20 mm (0.008 inch). If backlash is not within specifications transfer the necessary amount of shim thickness from one side of the axle housing to the other. 39. Verify differential case and ring gear runout by measuring ring to pinion gear backlash at several locations around the ring gear. Readings should not vary more than 0.05 mm. (0.002 inch). If readings vary more than specified, the ring gear or the differential case is defective. After the proper backlash is achieved, perform Gear Contact Pattern Analysis procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 Carrier Bearings: Service and Repair Rear Axle - 8 1/4 and 9 1/4 REMOVAL 1. Remove differential case from axle housing. 2. Remove the bearings from the differential case with Puller/Press C-293-PA and: Differential Bearing Removal-8 1/4 Axle - Adapters C-293-48 and Plug SP-3289 for the 8 1/4 axle. Differential Bearing Removal-9 1/4 Axle Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3875 - Adapters C-293-47 and Plug C-293-3 for the 9 1/4 axle. INSTALLATION 1. Install differential side bearings. Use: Install Differential Side Bearing-8 1/4 Axle - Installer C-4340 with handle C-4171 for the 8 1/4 axle. - Installer C-4213 and Handle C-4171 for the 9 1/4 axle. 2. Install differential case in axle housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3876 Carrier Bearings: Service and Repair Rear Axle - 248RBI REMOVAL 1. Remove differential case from axle housing. Differential Bearing Removal 2. Remove the bearings from the differential case with Puller/Press C-293-PA, Adapters C-293-62, and Step Plate C-4487-1. INSTALLATION Install Differential Side Bearings 1. Using tool C-4190 with handle C-4171, install differential side bearings. 2. Install differential case in axle housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Specifications Carrier Side Gears: Specifications Differential: Side Gear Clearance .............................................................................................................................................................. 0 - 0.18 mm (0 - 0.007 inch) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Specifications > Page 3880 Carrier Side Gears: Adjustments SIDE GEAR CLEARANCE When measuring side gear clearance, check each gear independently. If it necessary to replace a side gear, replace both gears as a matched set. 1. Install the axle shafts and C-clip locks and pinion mate shaft. Side Gear Clearance Measurement 2. Measure each side gear clearance. Insert a matched pair of feeler gauge blades between the gear and differential housing on opposite sides of the hub. 3. If side gear clearances is no more than 0.005 inch. Determine if the shaft is contacting the pinion gear mate shaft. Do not remove the feeler gauges, inspect the axle shaft with the feeler gauge inserted behind the side gear. If the end of the axle shaft is not contacting the pinion gear mate shaft, the side gear clearance is acceptable. Side Gear Calculations 4. If clearance is more than 0.005 inch (axle shaft not contacting mate shaft), record the side gear clearance. Remove the thrust washer and measure its thickness with a micrometer. Add the washer thickness to the recorded side gear clearance. The sum of gear clearance and washer thickness will determine required thickness of replacement thrust washer. In some cases, the end of the axle shaft will move and contact the mate shaft when the feeler gauge is inserted. The C-clip lock is preventing the side gear from sliding on the axle shaft. 5. If there is no side gear clearance, remove the C-clip lock from the axle shaft. Use a micrometer to measure the thrust washer thickness. Record the thickness and re-install the thrust washer. Assemble the differential case without the C-clip lock installed and re-measure the side gear clearance. 6. Compare both clearance measurements. If the difference is less than 0.012 inch (0.305 mm), add clearance recorded when the C-clip lock was installed to thrust washer thickness measured. The sum will determine the required thickness of the replacement thrust washer. 7. If clearance is 0.012 inch (0.305 mm) or greater, both side gears must be replaced (matched set) and the clearance measurements repeated. 8. If clearance (above) continues to be 0.012 inch (0.305 mm) or greater, the case must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications Differential Case: Specifications Differential Case: Clearance ............................................................................................................................................ ............................................. 0.12 mm (0.005 inch) Flange Runout .................................................... ............................................................................................................................ 0.076 mm (0.003 inch) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 Differential Case: Service and Repair Rear Axle - 8 1/4 and 9 1/4 REMOVAL 1. Remove the axle shafts. 2. Remove RWAL/ABS sensor from housing. NOTE: Side play resulting from bearing races being loose on case hubs requires replacement of the differential case. Mark For Installation Reference 3. Mark the differential housing and the differential bearing caps for installation reference. 4. Remove bearing threaded adjuster lock from each bearing cap. Loosen the bolts, but do not remove the bearing caps. Threaded Adjuster Tool 5. Loosen the threaded adjusters with Wrench C-4164. 6. Hold the differential case while removing bearing caps and adjusters. 7. Remove the differential case. NOTE: Each differential bearing cup and threaded adjuster must be kept with their respective bearing. INSTALLATION 1. Apply a coating of hypoid gear lubricant to the differential bearings, bearing cups, and threaded adjusters. A dab of grease can be used to keep the adjusters in position. Carefully position the assembled differential case in the housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3886 Bearing Caps & Bolts 2. Observe the reference marks and install the differential bearing caps at their original locations. 3. Install bearing cap bolts and tighten the upper bolts to 14 Nm (10 ft. lbs.). Tighten the lower bolts finger-tight until the bolt head is seated. 4. Perform the differential bearing pre-load and adjustment procedure. 5. Install axle shafts and differential housing cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3887 Differential Case: Service and Repair Rear Axle - 248RBI REMOVAL 1. Remove axle shafts. Bearing Cap Identification 2. Note the orientation of the installation reference letters stamped on the bearing caps and housing machined sealing surface. 3. Remove the differential bearing caps. Spread Differential Housing 4. Position Spreader W-129-B with the tool dowel pins seated in the locating holes. 5. Install the hold down clamps and tighten the tool turnbuckle finger-tight. 6. Install a Guide Pin C-3288-B at the left side of the differential housing. Attach dial indicator to housing pilot stud. Load the indicator plunger against the opposite side of the housing and zero the indicator. 7. Spread the housing enough to remove the case from the housing. Measure the distance with the dial indicator. CAUTION: Do not spread over 0.50 mm (0.020 in). If the housing is over-spread, it could be distorted or damaged. 8. Remove the dial indicator. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3888 Differential Removal 9. Pry the differential case loose from the housing. To prevent damage, pivot on housing with the end of the pry bar against spreader. 10. Remove the case from housing. Mark or tag bearing cups to indicate which side they were removed from. INSTALLATION 1. Position Spreader W-129-B with the tool dowel pins seated in the locating holes. Install the hold down clamps and tighten the tool turnbuckle finger-tight. 2. Install a Guide Pin C-3288-B at the left side of the differential housing. Attach dial indicator to housing pilot stud. Load the indicator plunger against the opposite side of the housing and zero the indicator. 3. Spread the housing enough to install the case in the housing. Measure the distance with the dial indicator. CAUTION: Do not spread over 0.50 mm (0.020 inch). If the housing is over-spread, it could be distorted or damaged. 4. Remove the dial indicator. 5. Install differential in housing. Differential Installation 6. Install case in the housing. Tap the differential case with a rawhide or rubber mallet to ensure the bearings are fully seated in the differential housing. 7. Remove the spreader. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3889 Differential Bearing Cap Reference Letters 8. Install the bearing caps at their original locations. Tighten the bearing cap bolts to 109 Nm (80 ft. lbs.) torque. 9. Install axle shafts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid Differential Cover: Technical Service Bulletins Differential Cover - Updated Sealer & Fluid NUMBER: 03-08-00 GROUP: Axle & Propeller Shaft DATE: Sep. 5, 2000 SUBJECT: RTV Use On Corporate Axle MODELS: NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH AN 8.25, 9.25, OR C205F CORPORATE AXLE. DISCUSSION: The axle lubricant used in all corporate axles was changed in formulation starting at the beginning of the 1998 model year. The corporate axles involved include: the 8.25 and 9.25 rear axles, and the C205F front axle. The new lubricant in use is SAE 75W-90 p/n 05010320AA. The lubricant change was made as a fuel economy improvement. The new axle lubricant is more chemically aggressive/reactive when in contact with the previous used Room Temperature Vulcanizable (RTV) sealant. Because of this condition, the RTV used in assembly of the pan/cover to the axle housing was revised and improved. When re-sealing axle covers, using the proper sealing material to minimize any potential sealant breakdown is important. The only recommended sealing material for all corporate axle covers is MOPAR RTV Sealant, p/n 05013477M. This RTV is red/orange in color. NOTE: IF SAE 75W-90 LUBRICANT IS USED TO REFILL ANY CORPORATE AXLE, THEN THE RED/ORANGE MOPAR RTV SEALANT, P/N 05013477AA, SHOULD BE USED TO SEAL THE COVER TO THE AXLE HOUSING. To optimize sealant performance and enhance adhesion, flanges should be clean and free of residual lubricant. The mating flanges should first be cleaned of any excess old RTV using a plastic putty knife. Final cleaning/degreasing shall be done by spraying MOPAR Brake Parts Cleaner, p/n 04549623, on the carrier and cover flanges, followed by a wipe with a clean dry cloth. Care should be taken to avoid spraying the parts cleaner inside the carrier. Once the RTV has been applied, the axle cover is to be installed to the housing within 3 to 5 minutes to prevent skinning over of the RTV. NOTE: IF THE AXLE COVER IS NOT INSTALLED WITHIN THE 3 TO 5 MINUTE TIME FRAME, THE CARRIER COVER FACE MUST BE RECLEANED AND NEW RTV APPLIED, OR ADHESION QUALITY WILL BE COMPROMISED. Immediately install the cover attaching bolts and tighten them to the specified torque to prevent a shimming effect by the RTV. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 Differential Cover: Service and Repair Rear Axle - 8 1/4 and 9 1/4 FINAL ASSEMBLY Typical Housing Cover With Sealant 1. Scrape the residual sealant from the housing and cover mating surfaces. Clean the mating surfaces with mineral spirits. Apply a bead of MOPAR(r) Silicone Rubber Sealant, or equivalent, on the housing cover. Install the housing cover within 5 minutes after applying the sealant. 2. Install the cover on the differential with the attaching bolts. Install the identification tag. Tighten the cover bolts to 41 Nm (30 ft. lbs.) torque. CAUTION: Overfilling the differential can result in lubricant foaming and overheating. 3. Refill the differential housing with gear lubricant. Refer to the Lubricant Specifications section for the gear lubricant requirements. 4. Install the fill hole plug. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3896 Differential Cover: Service and Repair Rear Axle - 248RBI FINAL ASSEMBLY Typical Housing Cover With Sealant 1. Scrape the residual sealant from the housing and cover mating surfaces. Clean the mating surfaces with mineral spirits. Apply a bead of MOPAR(R) Silicone Rubber Sealant, or equivalent, on the housing cover. Install the housing cover within 5 minutes after applying the sealant. 2. Install the cover on the differential with the attaching bolts. Install the identification tag. Tighten the cover bolts to 41 Nm (30 ft. lbs.) torque. CAUTION: Overfilling the differential can result in lubricant foaming and overheating. 3. Refill the differential housing with gear lubricant. Refer to the Lubricant Specifications section for the gear lubricant requirements. 4. Install the fill hole plug. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid Fluid - Differential: Technical Service Bulletins Differential Cover - Updated Sealer & Fluid NUMBER: 03-08-00 GROUP: Axle & Propeller Shaft DATE: Sep. 5, 2000 SUBJECT: RTV Use On Corporate Axle MODELS: NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH AN 8.25, 9.25, OR C205F CORPORATE AXLE. DISCUSSION: The axle lubricant used in all corporate axles was changed in formulation starting at the beginning of the 1998 model year. The corporate axles involved include: the 8.25 and 9.25 rear axles, and the C205F front axle. The new lubricant in use is SAE 75W-90 p/n 05010320AA. The lubricant change was made as a fuel economy improvement. The new axle lubricant is more chemically aggressive/reactive when in contact with the previous used Room Temperature Vulcanizable (RTV) sealant. Because of this condition, the RTV used in assembly of the pan/cover to the axle housing was revised and improved. When re-sealing axle covers, using the proper sealing material to minimize any potential sealant breakdown is important. The only recommended sealing material for all corporate axle covers is MOPAR RTV Sealant, p/n 05013477M. This RTV is red/orange in color. NOTE: IF SAE 75W-90 LUBRICANT IS USED TO REFILL ANY CORPORATE AXLE, THEN THE RED/ORANGE MOPAR RTV SEALANT, P/N 05013477AA, SHOULD BE USED TO SEAL THE COVER TO THE AXLE HOUSING. To optimize sealant performance and enhance adhesion, flanges should be clean and free of residual lubricant. The mating flanges should first be cleaned of any excess old RTV using a plastic putty knife. Final cleaning/degreasing shall be done by spraying MOPAR Brake Parts Cleaner, p/n 04549623, on the carrier and cover flanges, followed by a wipe with a clean dry cloth. Care should be taken to avoid spraying the parts cleaner inside the carrier. Once the RTV has been applied, the axle cover is to be installed to the housing within 3 to 5 minutes to prevent skinning over of the RTV. NOTE: IF THE AXLE COVER IS NOT INSTALLED WITHIN THE 3 TO 5 MINUTE TIME FRAME, THE CARRIER COVER FACE MUST BE RECLEANED AND NEW RTV APPLIED, OR ADHESION QUALITY WILL BE COMPROMISED. Immediately install the cover attaching bolts and tighten them to the specified torque to prevent a shimming effect by the RTV. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid > Page 3901 Fluid - Differential: Technical Service Bulletins Differential - Lubricant & Sealing Requirements NO: 03-02-98 GROUP: Axle And Propshaft DATE: Apr. 3, 1996 SUBJECT: 8-1/4 - 9-1/4 Axle Lubricant And Sealing Requirements MODELS: 1998 (AB) Ram Van 1998 (AN) Dakota 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1998 (XJ) Cherokee DISCUSSION: With the introduction of the 1998 model year, the axle lubricant in the 8-1/4 and 9-1/4 axles was changed in formulation to improve fuel economy. When adding lubricant or if service is performed that requires new lubricant use 75W90 p/n 5010320AA. This lubricant is more aggressive toward RTV sealants than previously used axle lubricants. When resealing the axle cover, using the proper sealing material to minimize any potential fluid foaming and/or seal breakdown is important. Currently the only recommended sealing material for mall axle covers or transmission pans is MOPAR RTV Sealant (grey in color) p/n 82300234. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity 8 1/4 ..................................................................................................................................................... ........................................................ 2.22L (4.7 pints) With TRAC-LOK .............................................. ..................................................................................................................... include 5 oz. friction modifier 9 1/4 ....................................................................................................................................... ...................................................................... 2.32L (4.9 pints) With TRAC-LOK ................................ ................................................................................................................................... include 5 oz. friction modifier 248RBI ....................................................................................................................... ............................................................................... 2.96L (6.25 pints) With TRAC-LOK ..................... .............................................................................................................................................. include 6 oz. friction modifier Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 3904 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Grade ................................................................................................................................................... ................................................................... API GL-5 Viscosity .............................................................................................................................................. ........................................................................... 90W TRAC-LOK differentials require the specified amount of friction modifier. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 3905 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > 8 1/4 Axle Pinion Bearing: Specifications 8 1/4 Axle Pinion Bearing: Preload ................................................................................................................................................ ........................................ 1-2 Nm (10-20 inch lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > 8 1/4 Axle > Page 3910 Pinion Bearing: Specifications 9 1/4 Axle Pinion Bearing Preload: Original ................................................................................................................................................ ....................................... 1-2 Nm (10-20 inch lbs.) New ...................................................................... ....................................................................................................................... 2-5 Nm (15-35 inch lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > 8 1/4 Axle > Page 3911 Pinion Bearing: Specifications Rear Axle - 248RBI Pinion Bearing Preload: Original Bearing ................................................................................................................................... ...................................... 1-3 Nm (10-20 inch lbs.) New Bearing ......................................................... ...................................................................................................................... 2-5 Nm (20-40 inch lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications Pinion Gear: Specifications SERVICE SPECIFICATIONS Pinion Std. Depth ................................................................................................................................. ............................................. 127 mm (5.000 inch) TORQUE SPECIFICATIONS Pinion Nut ............................................................................................................................................ .............................. 292-447 Nm (215-330 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > 8 1/4 Axle Pinion Gear: Adjustments 8 1/4 Axle GENERAL INFORMATION Pinion Gear ID Numbers Ring and pinion gears are supplied as matched sets only. The identifying numbers for the ring and pinion gear are marked on the face of each gear. A plus (+) number, minus (-) number or zero (0) is marked on the face of the pinion gear. This number is the amount (in thousandths of an inch) the depth varies from the standard depth setting of a pinion marked with a (0). The standard depth provides the best teeth contact pattern. Refer to Backlash and Contact Pattern Analysis Paragraph for additional information. Shim Locations Compensation for pinion depth variance is achieved with select shims. The shims are placed under the rear pinion bearing cone. If a new gear set is being installed, note the depth variance marked on both the original and replacement pinion gear. Add or subtract the thickness of the original depth shims to compensate for the difference in the depth variances. Refer to the Depth Variance charts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > 8 1/4 Axle > Page 3917 Note where Old and New Pinion Marking columns intersect. Intersecting figure represents plus or minus amount needed. Note the marked number on the face of the drive pinion gear (-1, -2, 0, +1, +2, etc.). The numbers represent thousands of an inch deviation from the standard. If the number is negative, add that value to the required thickness of the depth shim(s). If the number is positive, subtract that value from the thickness of the depth shim(s). If the number is 0 no change is necessary. Refer to the Pinion Gear Depth Variance Chart. PINION DEPTH MEASUREMENT AND ADJUSTMENT 1. Install front pinion bearing cup. Use Installer D-130 and Handle C-4171. 2. Install rear pinion bearing cup. Use Installer C-4308 and Handle C-4171. 8 1/4 Axle Pinion Adjustment Tools 3. Use Pinion Gear Adjustment Gauge Set C-3715-B. 4. Position Spacer SP-6030 over Shaft SP-5385. 5. Position pinion rear bearing on shaft. 6. Position tools (with bearing) in the housing. 7. Install Sleeve SP-5382. 8. Install pinion front bearing. 9. Install Spacer SP-6022. 10. Install Sleeve SP-3194-13, Washer SP-534, and Nut SP-3193. 11. Tighten the nut to seat the pinion bearings in the housing. Allow the sleeve to turn several times during tightening to prevent brinelling bearing cups or bearings. 12. Loosen the compression nut tool. 13. Lubricate the pinion gear front and rear bearings with gear lubricant. 14. Re-tighten the compression nut tool to 1-3 Nm (15-25 inch lbs.) torque. 15. Rotate the pinion gear several complete revolutions to align the bearing rollers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > 8 1/4 Axle > Page 3918 Gauge Block 16. Install Gauge Block. 17. Install Gauge Block SP-5383 at the end of SP-5385. 18. Install Cap Screw SP-536 and tighten with Wrench SP-531. Crossbore Arbor 19. Position Crossbore Arbor SP-6029 in the differential housing. 20. Center the arbor tool. 21. Position the bearing caps on the arbor tool. 22. Install the attaching bolts. 23. Tighten the cap bolts to 14 Nm (10 ft. lbs.). Depth Shim(s) Selection 24. Trial fit depth shim(s) between the crossbore arbor and gauge block. The depth shim(s) fit must be snug but not tight (drag friction of a feeler gauge blade). 25. Select a shim equal to the shim selected above plus the drive pinion gear depth variance number marked on the face of the pinion gear using the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > 8 1/4 Axle > Page 3919 opposite sign on the variance number. For example, if the depth variance is -2, add +0.002 inch to the dial indicator reading. NOTE: Depth shims are available in 0.001-inch increments from 0.020 inch to 0.038 inch. 26. Remove the tools from the differential housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > 8 1/4 Axle > Page 3920 Pinion Gear: Adjustments 9 1/4 Axle GENERAL INFORMATION Pinion Gear ID Numbers Ring and pinion gears are supplied as matched sets only. The identifying numbers for the ring and pinion gear are marked on the face of each gear. A plus (+) number, minus (-) number or zero (0) is marked on the face of the pinion gear. This number is the amount (in thousandths of an inch) the depth varies from the standard depth setting of a pinion marked with a (0). The standard depth provides the best teeth contact pattern. Refer to Backlash and Contact Pattern Analysis Paragraph for additional information. Shim Locations Compensation for pinion depth variance is achieved with select shims. The shims are placed under the rear pinion bearing cone. If a new gear set is being installed, note the depth variance marked on both the original and replacement pinion gear. Add or subtract the thickness of the original depth shims to compensate for the difference in the depth variances. Refer to the Depth Variance charts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > 8 1/4 Axle > Page 3921 Note where Old and New Pinion Marking columns intersect. Intersecting figure represents plus or minus amount needed. Note the marked number on the fan of the drive pinion gear (-1, -2, 0, +1, +2, etc.). The numbers represent thousands of an inch deviation from the standard. If the number is negative, add that value to the required thickness of the depth shim(s). If the number is positive, subtract that value from the thickness of the depth shim(s). If the number is 0 no change is necessary. Refer to the Pinion Gear Depth Variance Chart. PINION DEPTH MEASUREMENT AND ADJUSTMENT 1. Install front bearing cup. Use Installer D-129 and Handle C-4171. 2. Install rear bearing cup. Use Installer C-4310 and Handle C-4171. 9 1/4 Axle Pinion Adjustment Tools 3. Use Pinion Gear Adjustment Gauge Set C-758-D6. 4. Position Spacer SP-6017 over Shaft SP-526. 5. Position pinion rear bearing on shaft. 6. Position tools (with bearing) in the housing. 7. Install Sleeve SP-1730. 8. Install pinion front bearing. 9. Install Spacer SP-6022. 10. Install Sleeve SP-535A, Washer SP-534, and Nut SP-533. 11. Tighten the nut to seat the pinion bearings in the housing. Allow the sleeve to turn several times during tightening to prevent brinelling bearing cups or bearings. 12. Loosen the compression nut tool. 13. Lubricate the pinion gear front and rear bearings with gear lubricant. 14. Re-tighten the compression nut tool to 1-3 Nm (15-25 inch lbs.) torque. 15. Rotate the pinion gear several complete revolutions to align the bearing rollers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > 8 1/4 Axle > Page 3922 Gauge Block 16. Install Gauge Block. 17. Install Gauge Block SP-6020 at the end of SP-526. 18. Install Cap Screw SP-536 and tighten with Wrench SP-531. Crossbore Arbor 19. Position Crossbore Arbor SP-6018 in the differential housing. 20. Center the tool. 21. Position the bearing caps on the arbor tool. 22. Install the attaching bolts. 23. Tighten the cap bolts to 14 Nm (10 ft. lbs.). Depth Shim(s) Selection 24. Trial fit depth shim(s) between the crossbore arbor and gauge block. The depth shim(s) fit must be snug but not tight (drag friction of a feeler gauge blade). 25. Select a shim equal to the shim selected above plus the drive pinion gear depth variance number marked on the face of the pinion gear using the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > 8 1/4 Axle > Page 3923 opposite sign on the variance number. For example, if the depth variance is -2, add +0.002 in. to the dial indicator reading. NOTE: Depth shims are available in 0.001-inch increments from 0.020 inch to 0.038 inch. 26. Remove the tools from the differential housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > 8 1/4 Axle > Page 3924 Pinion Gear: Adjustments Rear Axle - 248RBI GENERAL INFORMATION Pinion Gear ID Numbers Ring and pinion gears are supplied as matched sets only. The identifying numbers for the ring and pinion gear are etched into the face of each gear. A plus (+) number, minus (-) number or zero (0) is etched into the face of the pinion gear. This number is the amount (in thousandths of an inch) the depth varies from the standard depth setting of a pinion etched with a (0). The standard setting from the center line of the ring gear to the back face of the pinion is 127.00 mm (5.000 inch). The standard depth provides the best teeth contact pattern. Refer to Backlash and Contact Pattern Analysis Paragraph for additional information. Shim Locations Compensation for pinion depth variance is achieved with select shims. The shims are placed under the inner pinion bearing cone. If a new gear set is being installed, note the depth variance etched into both the original and replacement pinion gear. Add or subtract the thickness of the original depth shims to compensate for the difference in the depth variances. Refer to the Depth Variance charts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > 8 1/4 Axle > Page 3925 Note where Old and New Pinion Marking columns intersect. Intersecting figure represents plus or minus amount needed. Note the etched number on the face of the drive pinion gear (-1, -2, 0, +1, +2, etc.). The numbers represent thousands of an inch deviation from the standard. If the number is negative, add that value to the required thickness of the depth shim(s). If the number is positive, subtract that value from the thickness of the depth shim(s). If the number is 0 no change is necessary. Refer to the Pinion Gear Depth Variance Chart. PINION DEPTH MEASUREMENT AND ADJUSTMENT Pinion Gear Depth Gauge Tools-Typical Measurements are taken with pinion cups and pinion bearings installed in housing. Take measurements with a Pinion Gauge Set 6730 and Dial Indicator C-3339. 1. Assemble Pinion Height Block 6739, Pinion Block 6736, and rear pinion bearing onto Screw 6741. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > 8 1/4 Axle > Page 3926 Pinion Height Block-Typical 2. Insert assembled height gauge components, rear bearing and screw into axle housing through pinion bearing cups. 3. Install front pinion bearing and Cone 6740 hand tight. Gauge Tools In Housing-Typical 4. Place Arbor Disc 6732 on Arbor D-115-3 in position in axle housing side bearing cradles. Install differential bearing caps on Arbor Discs and tighten cap bolts. Refer to the Torque Specifications. NOTE: Arbor Discs 6732 have different step diameters to fit other axle sizes. Pick correct size step for axle being serviced. 5. Assemble Dial Indicator C-3339 into Scooter Block D-115-2 and secure set screw. 6. Place Scooter Block/Dial Indicator in position in axle housing so dial probe and scooter block are flush against the surface of the pinion height block. Hold scooter block in place and zero the dial indicator face to the pointer. Tighten dial indicator face lock screw. 7. With scooter block still in position against the pinion height block, slowly slide the dial indicator probe over the edge of the pinion height block. Observe how many revolutions counterclockwise the dial pointer travels (approximately 0.125 inch) to the out-stop of the dial indicator. Pinion Gear Depth Measurement-Typical Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > 8 1/4 Axle > Page 3927 8. Slide the dial indicator probe across the gap between the pinion height block and the arbor bar with the scooter block against the pinion height block. When the dial probe contacts the arbor bar, the dial pointer will turn clockwise. Bring dial pointer back to zero against the arbor bar, do not turn dial face. Continue moving the dial probe to the crest of the arbor bar and record the highest reading. If the dial indicator can not achieve the zero reading, the rear bearing cup or the pinion depth gauge set is not installed correctly. 9. Select a shim equal to the dial indicator reading plus the drive pinion gear depth variance number etched in the face of the pinion gear using the opposite sign on the variance number. For example, if the depth variance is -2, add +0.002 in. to the dial indicator reading. 10. Remove the pinion depth gauge components from the axle housing Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 Pinion Gear: Service and Repair Rear Axle - 8 1/4 and 9 1/4 NOTE: The ring and pinion gears are serviced in a matched set. Do not replace the pinion gear without replacing the ring gear. REMOVAL 1. Remove differential from the axle housing. 2. Mark pinion yoke and propeller shaft for installation alignment. 3. Disconnect propeller shaft from pinion yoke. Using suitable wire, tie propeller shaft to underbody. 4. Using Yoke Holder 6719 to hold yoke and remove the pinion yoke nut and washer. Pinion Yoke Removal 5. Using Remover C-452, remove the pinion yoke from pinion shaft. 6. Partially install pinion nut onto pinion to protect the threads. Remove Pinion Gear 7. Remove the pinion gear from housing. Catch the pinion with your hand to prevent it from falling and being damaged. 8. Remove the pinion shaft seal with suitable pry tool or slide-hammer mounted screw. 9. Remove oil slinger, if equipped, and front pinion bearing. 10. Remove the front pinion bearing cup with: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3930 Front Bearing Cup Removal-8 1/4 Axle - Remover C-4345 and Handle C-4171 for the 8 1/4 axles. - Bearing Removal Tool Set 6310 and Adapter Foot 6310-9 for the 9 1/4 axles. Rear Bearing Cup Removal 11. Remove the rear bearing cup from housing. Use: - Remover C-4307 and Handle C-4171 for the 8 1/4 axle. - Remover C-4309 and Handle C-4171 for the 9 1/4 axle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3931 Collapsible Spacer 12. Remove the collapsible pre-load spacer. Rear Bearing Removal 13. Remove the rear bearing from the pinion with: - Puller/Press C-293-PA and Adapters C-293-47 for the 8 1/4 axle. - Puller/Press C-293-PA and Adapters C-293-37 for the 9 1/4 axle. Place 4 adapter blocks so they do not damage the bearing cage. 14. Remove the depth shims from the pinion gear shaft. Record the thickness of the depth shims. INSTALLATION 1. Apply MOPAR(r) Door Ease, or equivalent, stick lubricant to outside surface of bearing cup. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3932 Pinion Rear Bearing Cup Installation 2. Install the pinion rear bearing cup with: Installer C-4308 and Driver Handle C-4171 for the 8 1/4 axle. - Installer C-4310 and Driver Handle C-4171 for the 9 1/4 axle. 3. Ensure cup is correctly seated. 4. Apply Mopar8 Door Ease, or equivalent, stick lubricant to outside surface of bearing cup. Pinion Front Bearing Cup Installation 5. Install the pinion front bearing cup with: Installer D-130 and Handle C-4171 for the 8 1/4 axle. - Installer D-129 and Handle C-4171 for the 9 1/4 axle. 6. Install pinion front bearing, and oil slinger, if equipped. 7. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3933 Pinion Seal Installation-8 1/4 Axle - Installer C-4076-B and Handle C-4735-1 for the 8 1/4 axle. - Installer C-3860-A and Handle C-4171 for the 9 1/4 axle. NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve proper ring and pinion gear mesh. If the factory installed ring and pinion gears are reused, the pinion depth shim should not require replacement. If required, refer to Pinion Gear Depth to select the proper thickness shim before installing rear pinion bearing. 8. Place the proper thickness depth shim on the pinion gear. Shaft Rear Bearing Installation 9. Install the rear bearing and slinger, if equipped, on the pinion gear with: Installer 6448 for the 8 1/4 axle. - Installer C-3095 for the 9 1/4 axle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3934 Collapsible Preload Spacer 10. Install a new collapsible pre-load spacer on pinion shaft and install pinion gear in housing. 11. Install pinion gear in housing. 12. Install yoke with Installer C-3718 and Yoke Holder 6719. 13. Install the yoke washer and a new nut on the pinion gear and tighten the pinion nut until there is zero bearing end-play. It will not be possible at this point to achieve zero bearing end-play if a new collapsible spacer was installed. 14. Tighten the nut to 285 Nm (210 ft. lbs.). CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified pre-load torque. If pre-load torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated. 15. Using Yoke Holder 6719, crush collapsible spacer until bearing end play is taken up. Check Pinion Gear Rotating Torque 16. Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer. 17. Check bearing rotating torque with an inch pound torque wrench. The torque necessary to rotate the pinion gear should be: - Original Bearings - 1 to 3 Nm (10 to 20 inch lbs.). - New Bearings - 2 to 5 Nm (15 to 35 inch lbs.). 18. Install propeller shaft. 19. Install differential in housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3935 Pinion Gear: Service and Repair Rear Axle - 248RBI NOTE: The ring and pinion gears are service in a matched set. Do not replace the pinion gear without replacing the ring gear. REMOVAL 1. Remove differential assembly from axle housing. 2. Mark pinion yoke and propeller shaft for installation alignment. 3. Disconnect propeller shaft from pinion yoke. Using suitable wire, tie propeller shaft to underbody. 4. Using Yoke Holder 6719 to hold yoke, remove the pinion yoke nut and washer. Pinion Yoke Removal 5. Using Remover C-452 and Wrench C-3281, remove the pinion yoke from pinion shaft. Remove Pinion Gear 6. Remove the pinion gear from housing. Catch the pinion with your hand to prevent it from falling and being damaged. 7. Remove the pinion seal with a slide hammer or suitable pry bar. 8. Remove oil slinger, if equipped, and the front pinion bearing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3936 Front Bearig Cup Removal 9. Remove the front pinion bearing cup with Remover D-158 and Handle C-4171. Rear Bearing Cup Removal 10. Remove the rear bearing cup from housing. Use Remover D-162 and Handle C-4171. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3937 Collapsible Spacer 11. Remove the collapsible pre-load spacer. Inner Bearing Removal 12. Remove the rear bearing from the pinion with Puller/Press C-293-PA and Adapters C-293-37. Place 4 adapter blocks so they do not damage the bearing cage. 13. Remove the pinion depth shims from the pinion gear shaft. Record the total thickness of the depth shims. INSTALLATION Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3938 Pinion Rear Bearing Cup Installation 1. Apply MOPAR(r) Door Ease stick lubricant to outside surface of bearing cup. Install the pinion rear bearing cup with Installer D-111 and Handle C-4171. Ensure cup is correctly seated. Pinion Front Bearing Cup Installation 2. Apply MOPAR(r) Door Ease stick lubricant to outside surface of bearing cup. Install the pinion front bearing cup with Installer D-146 and Handle C-4171. 3. Install pinion front bearing and oil slinger, if equipped. Apply a light coating of gear lubricant on the lip of pinion seal. Pinion Seal Installation 4. Install seal with Installer 8108 and Handle C-4171. NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve proper ring and pinion gear mesh. If the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3939 factory installed ring and pinion gears are reused, the pinion depth shim should not require replacement or adjustment. Refer to Pinion Gear Depth paragraph to select the proper thickness shim before installing rear pinion bearing cone. 5. Place the proper thickness pinion depth shim on the pinion gear. Shaft Rear Bearing Installation 6. Install the rear bearing and oil slinger, if equipped, on the pinion gear with Installer C-3095-A. Collapsible Preload Spacer 7. Install a new collapsible pre-load spacer on pinion shaft. 8. Install pinion gear in housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3940 Pinion Yoke Installation 9. Install yoke with Installer C-3718 and Yoke Holder 6719. 10. Install the yoke washer and a new nut on the pinion gear. Tighten the nut to 292 Nm (215 ft. lbs.) minimum. Do not over-tighten. Maximum torque is 447 Nm (330 ft. lbs.). CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing pre-load torque and never exceed specified pre-load torque. If pre-load torque is exceeded a new collapsible spacer must be installed. The torque sequence will have to be repeated. Tightening Pinion Nut 11. Using Yoke Holder 6719, and a torque wrench set at 447 Nm (330 ft. lbs.), crush collapsible spacer until bearing end play is taken up. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3941 Check Pinion Gear Rotation Torque 12. Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer. 13. Check bearing rotating torque with an inch pound torque wrench. The torque necessary to rotate the pinion gear should be: - Original Bearings - 1 to 3 Nm (10 to 20 inch lbs.). - New Bearings - 2 to 5 Nm (15 to 35 inch lbs.). 14. Align previously made marks on Yoke and propeller shaft and install propeller shaft. 15. Install differential housing into the axle housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Rear Axle - 9 1/4 Ring Gear: Specifications Rear Axle - 9 1/4 SERVICE SPECIFICATIONS Ring Gear: Diameter .............................................................................................................................................. ........................................ 23.50 cm (9.25 inch) Backlash ................................................................... ............................................................................................... 0.12-0.20 mm (0.005-0.008 inch) Runout ................................................................................................................................................. .................................... 0.127 mm (0.005 inch) TORQUE SPECIFICATIONS Ring Gear Bolt ..................................................................................................................................... ............................................ 157 Nm (11.5 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Rear Axle - 9 1/4 > Page 3946 Ring Gear: Specifications Rear Axle - 248RBI SERVICE SPECIFICATIONS Ring Gear: Diameter .............................................................................................................................................. ........................................ 24.76 cm (9.75 inch) TORQUE SPECIFICATIONS Ring Gear Bolt ..................................................................................................................................... .............................. 163-190 Nm (120-140 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Rear Axle - 9 1/4 > Page 3947 Ring Gear: Specifications 8 1/4 Axle SERVICE SPECIFICATIONS Ring Gear: Diameter .............................................................................................................................................. ........................................ 20.95 cm (8.25 inch) Backlash ................................................................... ............................................................................................. 0.12-0.20 mm (0.005-01.008 inch) Runout ................................................................................................................................................. .................................... 0.127 mm (0.005 inch) TORQUE SPECIFICATIONS Ring Gear Bolt ..................................................................................................................................... ............................................... 102 Nm (75 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Adjustments > Rear Axle - 8 1/4 and 9 1/4 Ring Gear: Adjustments Rear Axle - 8 1/4 and 9 1/4 GEAR CONTACT PATTERN ANALYSIS The ring and pinion gear teeth contact patterns will show if the pinion gear depth is correct in the axle housing. It will also show if the ring gear backlash has been adjusted correctly. The backlash can be adjusted within specifications to achieve desired tooth contact patterns. 1. Apply a thin coat of hydrated ferric oxide, or equivalent, to the drive and coast side of the ring gear teeth. 2. Wrap, twist, and hold a shop towel around the pinion yoke to increase the turning resistance of the pinion gear. This will provide a more distinct contact pattern. 3. Using a boxed end wrench on a ring gear bolt, Rotate the differential case one complete revolution in both directions while a load is being applied from shop towel. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Adjustments > Rear Axle - 8 1/4 and 9 1/4 > Page 3950 Gear Tooth Contact Patterns The areas on the ring gear teeth with the greatest degree of contact against the pinion gear teeth will squeegee the compound to the areas with the least amount of contact. Note and compare patterns on the ring gear teeth to Gear Tooth Contact Patterns chart and adjust pinion depth and gear backlash as necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Adjustments > Rear Axle - 8 1/4 and 9 1/4 > Page 3951 Ring Gear: Adjustments Rear Axle - 248RBI GEAR CONTACT PATTERN ANALYSIS The ring and pinion gear teeth contact patterns will show if the pinion gear depth is correct in the axle housing. It will also show if the ring gear backlash has been adjusted correctly. The backlash can be adjusted within specifications to achieve desired tooth contact patterns. 1. Apply a thin coat of hydrated ferric oxide, or equivalent, to the drive and coast side of the ring gear teeth. 2. Wrap, twist, and hold a shop towel around the pinion yoke to increase the turning resistance of the pinion gear. This will provide a more distinct contact pattern. 3. Using a boxed end wrench on a ring gear bolt, rotate the differential case one complete revolution in both directions while a load is being applied from shop towel. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Adjustments > Rear Axle - 8 1/4 and 9 1/4 > Page 3952 Gear Tooth Contact Patterns The areas on the ring gear teeth with the greatest degree of contact against the pinion gear teeth will squeegee the compound to the areas with the least amount of contact. Note and compare patterns on the ring gear teeth to Gear Tooth Contact Patterns chart and adjust pinion depth and gear backlash as necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 Ring Gear: Service and Repair Rear Axle - 8 1/4 and 9 1/4 NOTE: The ring and pinion gears are serviced in a matched set. Do not replace the ring gear without replacing the pinion gear. REMOVAL 1. Remove differential from axle housing. Ring Gear Removal 2. Place differential case in a suitable vise with soft metal jaw protectors. 3. Remove bolts holding ring gear to differential case. 4. Using a soft hammer, drive ring gear from differential case. 5. Use a brass drift and slowly tap the exciter ring from the differential case. INSTALLATION CAUTION: Do not reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage. 1. Invert the differential case. 2. Position exciter ring on differential case. 3. Using a brass drift, slowly and evenly tap the exciter ring into position. 4. Position ring gear on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. 5. Invert the differential case in the vise. Ring Gear Bolt Installation 6. Install new ring gear bolts and alternately tighten to 157 Nm (115 ft. lbs.) torque. 7. Install differential in axle housing and verify gear mesh and contact pattern. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3955 Ring Gear: Service and Repair Rear Axle - 248RBI The ring and pinion gears are service in a matched set. Do not replace the ring gear without replacing the pinion gear. REMOVAL 1. Remove differential from axle housing. Ring Gear Removal 2. Place differential case in a suitable vise with soft metal jaw protectors. 3. Remove bolts holding ring gear to differential case. 4. Using a soft hammer, drive ring gear from differential case. 5. Use a brass drift and slowly tap the exciter ring from the differential case. INSTALLATION CAUTION: Do not reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage. 1. Invert the differential case. 2. Position exciter ring on differential case. 3. Using a brass drift, slowly and evenly tap the exciter ring into position. 4. Invert the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. 5. Invert the differential case in the vise. Ring Gear Bolt Installation 6. Install new ring gear bolts and alternately tighten to 163-190 Nm (120-140 ft. lbs.) torque. 7. Install differential in axle housing and verify gear mesh and contact pattern. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 8 1/4 or 9 1/4 Seals and Gaskets: Service and Repair Rear Axle - 8 1/4 or 9 1/4 REMOVAL 1. Raise and support the vehicle. 2. Scribe a mark on the universal joint, pinion yoke, and pinion shaft for reference. 3. Disconnect the propeller shaft from the pinion yoke. Secure the propeller shaft in an upright position to prevent damage to the rear universal joint. 4. Remove the wheel and tire assemblies. 5. Remove the brake drums to prevent any drag. The drag may cause a false bearing rotating torque measurement. 6. Rotate the pinion yoke three or four times. 7. Measure the amount of torque necessary to rotate the pinion gear with a (inch lbs.) dial-type torque wrench. Record the torque reading for installation reference. 8. Hold the yoke with Wrench 6719. Remove the pinion shaft nut and washer. Yoke Removal 9. Remove the yoke with Remover C-452. 10. Remove the pinion shaft seal with suitable pry tool or slide-hammer mounted screw. INSTALLATION 1. Clean the seal contact surface in the housing bore. 2. Examine the splines on the pinion shaft for burrs or wear. Remove any burrs and clean the shaft. 3. Inspect pinion yoke for cracks, worn splines and worn seal contact surface. Replace yoke if necessary. NOTE: The outer perimeter of the seal is pre-coated with a special sealant. An additional application of sealant is not required. 4. Apply a light coating of gear lubricant on the lip of pinion seal. 5. Install the new pinion shaft seal with: 8 1/4 Axle Pinion Seal Installation - 8 1/4 axle: Installer C-4076-B and Handle C-4735-1. - 9 9 1/4 axle: Installer C-3860-A and Handle C-4171. NOTE: The seal is correctly installed when the seal flange contacts the face of the differential housing flange. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 8 1/4 or 9 1/4 > Page 3960 6. Position the pinion yoke on the end of the shaft with the reference marks aligned. 7. Seat yoke on pinion shaft with Installer C-3718 and Wrench 6719. 8. Remove the tools and install the pinion yoke washer. The convex side of the washer must face outward. CAUTION: Do not exceed the minimum tightening torque when installing the pinion yoke retaining nut at this point. Damage to collapsible spacer or bearings may result. Tightening Pinion Shaft Nut 9. Hold pinion yoke with Yoke Holder 6719 and tighten shaft nut to 285 Nm (210 ft. lbs.). Rotate pinion shaft several revolutions to ensure the bearing rollers are seated. Check Pinion Rotation Torque 10. Rotate the pinion shaft using an (inch lbs.) torque wrench. Rotating torque should be equal to the reading recorded during removal, plus an additional 0.56 Nm (5 inch lbs.) . CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified pre-load torque. If pre-load torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated. 11. If the rotating torque is low, use Yoke Holder 6719 to hold the pinion yoke and tighten the pinion shaft nut in 6.8 Nm (5 ft. lbs.) increments until proper rotating torque is achieved. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 8 1/4 or 9 1/4 > Page 3961 NOTE: The bearing rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition. 12. The seal replacement is unacceptable if the final pinion nut torque is less than 285 Nm (210 ft. lbs.). 13. Install the propeller shaft with the installation reference marks aligned. 14. Tighten the universal joint yoke clamp screws to 19 Nm (14 ft. lbs.). 15. Install the brake drums. 16. Install wheel and tire assemblies and lower the vehicle. 17. Check the differential housing lubricant level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 8 1/4 or 9 1/4 > Page 3962 Seals and Gaskets: Service and Repair Rear Axle - 248RBI REMOVAL 1. Raise and support the vehicle. 2. Scribe a mark on the universal joint, pinion yoke, and pinion shaft for reference. 3. Disconnect the propeller shaft from the pinion yoke. Secure the propeller shaft in an upright position to prevent damage to the rear universal joint. 4. Remove the wheel and tire assemblies. 5. Remove the brake drums to prevent any drag. The drag may cause a false bearing pre-load torque measurement. 6. Rotate the pinion yoke three or four times. 7. Measure the amount of torque necessary to rotate the pinion gear with a (inch lbs.) dial-type torque wrench. Record the torque reading for installation reference. 8. Hold the yoke with Wrench 6719, Remove the pinion shaft nut and washer. Yoke Removal 9. Remove the yoke with Remover C-452. 10. Remove the pinion shaft seal with suitable pry tool or slide-hammer mounted screw. INSTALLATION 1. Clean the seal contact surface in the housing bore. 2. Examine the splines on the pinion shaft for burrs or wear. Remove any burrs and clean the shaft. 3. Inspect pinion yoke for cracks, worn splines and worn seal contact surface. Replace yoke if necessary. NOTE: The outer perimeter of the seal is pre-coated with a special sealant. An additional application of sealant is not required. 4. Apply a light coating of gear lubricant on the lip of pinion seal. Pinion Seal Installation 5. Install the new pinion shaft seal with Installer 8108 and Handle 4171. NOTE: The seal is correctly installed when the seal flange contacts the face of the differential housing flange. 6. Position the pinion yoke on the end of the shaft with the reference marks aligned. 7. Seat yoke on pinion shaft with Installer C-3718 and Wrench 6719. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 8 1/4 or 9 1/4 > Page 3963 8. Remove the tools and install the pinion yoke washer. CAUTION: Do not exceed the minimum tightening torque when installing the pinion yoke retaining nut at this point. Damage to collapsible spacer or bearings may result. Tightening Pinion Shaft Nut 9. Hold pinion yoke with Yoke Holder 6719 and tighten shaft nut to 291.5 Nm (215 ft. lbs.). Rotate pinion shaft several revolutions to ensure the bearing rollers are seated. Check Pinion Rotation Torque 10. Rotate the pinion shaft using a (inch lbs.) torque wrench. Rotating resistance torque should be equal to the reading recorded during removal, plus an additional 0.56 Nm (5 inch lbs.). CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified pre-load torque. If pre-load torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated. 11. If the rotating torque is low, use Yoke Holder 6719 to hold the pinion yoke and tighten the pinion shaft nut in 6.8 Nm (5 ft. lbs.) increments until proper rotating torque is achieved. NOTE: The bearing rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 8 1/4 or 9 1/4 > Page 3964 12. Install the propeller shaft with the installation reference marks aligned. 13. Tighten the universal joint yoke clamp screws to 19 Nm (14 ft. lbs.). 14. Install the brake drums. 15. Add gear lubricant to the differential housing, if necessary. Refer to the Lubricant Specifications for gear lubricant requirements. 16. Install wheel and tire assemblies and lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Technical Service Bulletins > Customer Interest for Axle Bearing: > 05-07-98 > Feb > 99 > Brakes Vibration/Shudder on Application Technical Service Bulletin # 05-07-98 Date: 990201 Brakes - Vibration/Shudder on Application NO: 05-07-98 GROUP: Brakes DATE: Feb. 1, 1999 SUBJECT: Vehicle Vibrates/Shudders When Brakes Are Applied MODELS: 1998 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 250013500 RAM VANS EQUIPPED WITH THE 9.25 HD AXLE (SALES CODE DRG). SYMPTOM/CONDITION: Vehicle vibrates/shudders when the brakes are applied. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 03-20-01-94 Remove and Install Axle Shafts, Measure Drum Diameter and Runout, Adjust Rear Brakes, Adjust Parking Brake Brake 1.0 Hrs. Related Operations: NOTE: OPERATIONS INCLUDE REPLACING BRAKE DRUMS WHEN NECESSARY. 03-20-20-50 Replace Axle Bearing and Seal, Right Side 0.2 Hrs. 03-20-20-51 Replace Axle Bearing and Seal, Left Side 0.2 Hrs. 03-20-26-50 Replace Axle Seal, Right Side 0.1 Hrs. 03-20-26-51 Replace Axle Seal, Left Side 0.1 Hrs. 05-70-06-59 Replace Brake Shoes And Linings 0.4 Hrs. 05-20-26-51 Resurface One Brake Drum 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Technical Service Bulletins > Customer Interest for Axle Bearing: > 05-07-98 > Feb > 99 > Brakes Vibration/Shudder on Application > Page 3974 05-20-26-52 Resurface Both Brake Drums 0.7 Hrs. FAILURE CODE: P8 - New Part Diagnosis 1. Drive the vehicle at a safe speed and apply the service brakes. If the vehicle does not vibrate/shudder until the brakes are applied, proceed to the next step. If the vehicle vibrates/shudder regardless of service brake operation, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for noise and vibration diagnosis in Groups 02, 03, 05, 09, 11, 19, and 22. 2. Drive the vehicle at a safe speed in area free of traffic. Lightly apply the parking brake. If the vehicle vibrates/shudder while the parking brake is applied, proceed to the next step. If the vehicle does not vibrate/shudder while the parking brake is applied, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for front brake vibration diagnosis in Group 05. 3. Raise the vehicle on a suitable hoist. NOTE: MAKE SURE THE PARKING BRAKE IS NOT APPLIED PRIOR TO LIFTING THE VEHICLE ON A HOIST. 4. Remove both right and left rear tire/wheel assemblies. 5. Remove both right and left rear brake drums. 6. Using a 100 - 125 mm (4-5 in.) micrometer or vernier caliper, measure the diameter of the brake drum pilot on the axle shaft (Figure 1). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Technical Service Bulletins > Customer Interest for Axle Bearing: > 05-07-98 > Feb > 99 > Brakes Vibration/Shudder on Application > Page 3975 7. If the brake drum pilot is less than 122.7 mm (4.830 in.) (Figure 2), perform the Repair Procedure. If the brake drum pilot is equal to or greater than 122.7 mm (4.830 in.), refer to the 1998 Ram Van Service Manual (Publication No. 81-370- 8107), pages 5-5 through 5-11 for information regarding brake system Diagnosis and Testing. Repair Procedure This bulletin involves installing revised axle shafts and if necessary brake linings and drums. 1. Clean all foreign material from the axle housing cover area. 2. Position a drain pan under the axle housing cover area. 3. Loosen housing cover bolts. Drain the lubricant from the housing and axle shaft tubes. Remove the housing cover. 4. Remove the original sealant from the housing and cover surfaces then, clean the cover surfaces with Mopar Brake parts Cleaner p/n 04549623. 5. Rotate the differential case so that the pinion mate gear shaft lock screw is accessible. Remove the lock screw and pinion mate gear shaft from the differential case (Figure 3). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Technical Service Bulletins > Customer Interest for Axle Bearing: > 05-07-98 > Feb > 99 > Brakes Vibration/Shudder on Application > Page 3976 6. Push the axle shaft inward and remove the axle shaft C-clip lock from the axle shaft (Figure 4.). 7. Remove axle shaft. Use care to prevent damage to the axle shaft bearing and seal, which will remain in the axle shaft tube. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 8. Inspect the axle shaft seal for leakage or damage and inspect the roller bearing contact surface on axle shaft for signs of brinelling, galling, and/or pitting. Replace the seal and/or bearing as necessary using p/n 04137314 for the seal and p/n 04117858 for the bearing. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 3-20 and 3-21 for Axle Seal And Bearing service. 9. Lubricate bearing bore and seal lip with gear lubricant p/n 05010320AA. Insert the new axle shaft p/n 041 17897AB through the seal and bearing, then engage the axle shaft splines into the side gear splines. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 10. Insert the C-clip lock onto the end of the axle shaft. Push axle shaft outward to seat the C-clip lock in the side gear. 11. Perform Steps 6 through 10 to the other axle shaft. 12. Insert pinion mate shaft into differential case and through thrust washers and pinion gears. 13. Align the hole in the shaft with the hole in the differential case. Apply Lock & Seal Adhesive p/n 04318031 to the threads of the pinion mate shaft lock screw and install the lock screw into the differential case. Tighten the screw to 11 Nm (8 ft. lbs). 14. Apply a bead of Mopar Silicone Sealant p/n 82300234 to the housing cover (Figure 5). The silicone sealant must be applied to all mating surfaces of the cover including around the cover bolt holes. NOTE: INSTALL THE COVER WITHIN FIVE MINUTES AFTER APPLYING THE SEALANT. 15. Install the cover and any identification tag. Tighten the cover attaching bolts to 44 Nm (33 ft. lbs.). 16. Fill the differential with 2.32 L (4.9 pts.) of Mopar 75W/90 Gear Lubricant p/n 0501 0320AA. 17. Inspect the brake linings on both sides of the vehicle. Replace the brake linings as necessary using p/n 05003999AA. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-21 through 5-22 for Rear Brake Shoes - 12 1/8 inch Removal and Installation. Anytime brake linings are replaced, new brake adjusting lever pins p/n 03492671 must be installed. 18. Measure brake drum diameter and runout. Brake drum diameter must be checked using an accurate brake drum micrometer. The maximum allowable diameter of the drum braking surface is indicated on the drum outer edge. Brake drum runout must be checked by mounting the drum onto a brake lathe and checking variation using a dial indicator. Variation in drum diameter should not exceed 0.076 mm (0.003 in.). Drum runout should not exceed 0.20 mm (0.008 in.) out of round. If the drum exceeds the variation/runout specification but does not exceed the maximum allowable diameter, resurface the brake drum. If the brake drum exceeds the maximum allowable diameter, replace the brake drum with p/n 5200951 9AC. If the brake drum is less than the maximum allowable variation/runout and the diameter of the drum is less than the maximum specification and there is not any major scoring in the drum, the drum can be reused. 19. Adjust brake shoes to brake drum using a brake gauge. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Technical Service Bulletins > Customer Interest for Axle Bearing: > 05-07-98 > Feb > 99 > Brakes Vibration/Shudder on Application > Page 3977 and 5-30 for information regarding proper brake shoe adjustment. 20. Install the brake drum onto the vehicle. 21. Install the tire and wheels onto the vehicle. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 22-8 and 22-9 for proper tire/wheel installation. 22. Adjust the park brake cable tension. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-30 and 5-31 for information regarding proper parking brake cable tension adjustment. 23. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Bearing: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application Technical Service Bulletin # 05-07-98 Date: 990201 Brakes - Vibration/Shudder on Application NO: 05-07-98 GROUP: Brakes DATE: Feb. 1, 1999 SUBJECT: Vehicle Vibrates/Shudders When Brakes Are Applied MODELS: 1998 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 250013500 RAM VANS EQUIPPED WITH THE 9.25 HD AXLE (SALES CODE DRG). SYMPTOM/CONDITION: Vehicle vibrates/shudders when the brakes are applied. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 03-20-01-94 Remove and Install Axle Shafts, Measure Drum Diameter and Runout, Adjust Rear Brakes, Adjust Parking Brake Brake 1.0 Hrs. Related Operations: NOTE: OPERATIONS INCLUDE REPLACING BRAKE DRUMS WHEN NECESSARY. 03-20-20-50 Replace Axle Bearing and Seal, Right Side 0.2 Hrs. 03-20-20-51 Replace Axle Bearing and Seal, Left Side 0.2 Hrs. 03-20-26-50 Replace Axle Seal, Right Side 0.1 Hrs. 03-20-26-51 Replace Axle Seal, Left Side 0.1 Hrs. 05-70-06-59 Replace Brake Shoes And Linings 0.4 Hrs. 05-20-26-51 Resurface One Brake Drum 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Bearing: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 3983 05-20-26-52 Resurface Both Brake Drums 0.7 Hrs. FAILURE CODE: P8 - New Part Diagnosis 1. Drive the vehicle at a safe speed and apply the service brakes. If the vehicle does not vibrate/shudder until the brakes are applied, proceed to the next step. If the vehicle vibrates/shudder regardless of service brake operation, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for noise and vibration diagnosis in Groups 02, 03, 05, 09, 11, 19, and 22. 2. Drive the vehicle at a safe speed in area free of traffic. Lightly apply the parking brake. If the vehicle vibrates/shudder while the parking brake is applied, proceed to the next step. If the vehicle does not vibrate/shudder while the parking brake is applied, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for front brake vibration diagnosis in Group 05. 3. Raise the vehicle on a suitable hoist. NOTE: MAKE SURE THE PARKING BRAKE IS NOT APPLIED PRIOR TO LIFTING THE VEHICLE ON A HOIST. 4. Remove both right and left rear tire/wheel assemblies. 5. Remove both right and left rear brake drums. 6. Using a 100 - 125 mm (4-5 in.) micrometer or vernier caliper, measure the diameter of the brake drum pilot on the axle shaft (Figure 1). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Bearing: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 3984 7. If the brake drum pilot is less than 122.7 mm (4.830 in.) (Figure 2), perform the Repair Procedure. If the brake drum pilot is equal to or greater than 122.7 mm (4.830 in.), refer to the 1998 Ram Van Service Manual (Publication No. 81-370- 8107), pages 5-5 through 5-11 for information regarding brake system Diagnosis and Testing. Repair Procedure This bulletin involves installing revised axle shafts and if necessary brake linings and drums. 1. Clean all foreign material from the axle housing cover area. 2. Position a drain pan under the axle housing cover area. 3. Loosen housing cover bolts. Drain the lubricant from the housing and axle shaft tubes. Remove the housing cover. 4. Remove the original sealant from the housing and cover surfaces then, clean the cover surfaces with Mopar Brake parts Cleaner p/n 04549623. 5. Rotate the differential case so that the pinion mate gear shaft lock screw is accessible. Remove the lock screw and pinion mate gear shaft from the differential case (Figure 3). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Bearing: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 3985 6. Push the axle shaft inward and remove the axle shaft C-clip lock from the axle shaft (Figure 4.). 7. Remove axle shaft. Use care to prevent damage to the axle shaft bearing and seal, which will remain in the axle shaft tube. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 8. Inspect the axle shaft seal for leakage or damage and inspect the roller bearing contact surface on axle shaft for signs of brinelling, galling, and/or pitting. Replace the seal and/or bearing as necessary using p/n 04137314 for the seal and p/n 04117858 for the bearing. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 3-20 and 3-21 for Axle Seal And Bearing service. 9. Lubricate bearing bore and seal lip with gear lubricant p/n 05010320AA. Insert the new axle shaft p/n 041 17897AB through the seal and bearing, then engage the axle shaft splines into the side gear splines. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 10. Insert the C-clip lock onto the end of the axle shaft. Push axle shaft outward to seat the C-clip lock in the side gear. 11. Perform Steps 6 through 10 to the other axle shaft. 12. Insert pinion mate shaft into differential case and through thrust washers and pinion gears. 13. Align the hole in the shaft with the hole in the differential case. Apply Lock & Seal Adhesive p/n 04318031 to the threads of the pinion mate shaft lock screw and install the lock screw into the differential case. Tighten the screw to 11 Nm (8 ft. lbs). 14. Apply a bead of Mopar Silicone Sealant p/n 82300234 to the housing cover (Figure 5). The silicone sealant must be applied to all mating surfaces of the cover including around the cover bolt holes. NOTE: INSTALL THE COVER WITHIN FIVE MINUTES AFTER APPLYING THE SEALANT. 15. Install the cover and any identification tag. Tighten the cover attaching bolts to 44 Nm (33 ft. lbs.). 16. Fill the differential with 2.32 L (4.9 pts.) of Mopar 75W/90 Gear Lubricant p/n 0501 0320AA. 17. Inspect the brake linings on both sides of the vehicle. Replace the brake linings as necessary using p/n 05003999AA. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-21 through 5-22 for Rear Brake Shoes - 12 1/8 inch Removal and Installation. Anytime brake linings are replaced, new brake adjusting lever pins p/n 03492671 must be installed. 18. Measure brake drum diameter and runout. Brake drum diameter must be checked using an accurate brake drum micrometer. The maximum allowable diameter of the drum braking surface is indicated on the drum outer edge. Brake drum runout must be checked by mounting the drum onto a brake lathe and checking variation using a dial indicator. Variation in drum diameter should not exceed 0.076 mm (0.003 in.). Drum runout should not exceed 0.20 mm (0.008 in.) out of round. If the drum exceeds the variation/runout specification but does not exceed the maximum allowable diameter, resurface the brake drum. If the brake drum exceeds the maximum allowable diameter, replace the brake drum with p/n 5200951 9AC. If the brake drum is less than the maximum allowable variation/runout and the diameter of the drum is less than the maximum specification and there is not any major scoring in the drum, the drum can be reused. 19. Adjust brake shoes to brake drum using a brake gauge. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Bearing: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 3986 and 5-30 for information regarding proper brake shoe adjustment. 20. Install the brake drum onto the vehicle. 21. Install the tire and wheels onto the vehicle. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 22-8 and 22-9 for proper tire/wheel installation. 22. Adjust the park brake cable tension. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-30 and 5-31 for information regarding proper parking brake cable tension adjustment. 23. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application Technical Service Bulletin # 05-07-98 Date: 990201 Brakes - Vibration/Shudder on Application NO: 05-07-98 GROUP: Brakes DATE: Feb. 1, 1999 SUBJECT: Vehicle Vibrates/Shudders When Brakes Are Applied MODELS: 1998 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 250013500 RAM VANS EQUIPPED WITH THE 9.25 HD AXLE (SALES CODE DRG). SYMPTOM/CONDITION: Vehicle vibrates/shudders when the brakes are applied. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 03-20-01-94 Remove and Install Axle Shafts, Measure Drum Diameter and Runout, Adjust Rear Brakes, Adjust Parking Brake Brake 1.0 Hrs. Related Operations: NOTE: OPERATIONS INCLUDE REPLACING BRAKE DRUMS WHEN NECESSARY. 03-20-20-50 Replace Axle Bearing and Seal, Right Side 0.2 Hrs. 03-20-20-51 Replace Axle Bearing and Seal, Left Side 0.2 Hrs. 03-20-26-50 Replace Axle Seal, Right Side 0.1 Hrs. 03-20-26-51 Replace Axle Seal, Left Side 0.1 Hrs. 05-70-06-59 Replace Brake Shoes And Linings 0.4 Hrs. 05-20-26-51 Resurface One Brake Drum 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 3996 05-20-26-52 Resurface Both Brake Drums 0.7 Hrs. FAILURE CODE: P8 - New Part Diagnosis 1. Drive the vehicle at a safe speed and apply the service brakes. If the vehicle does not vibrate/shudder until the brakes are applied, proceed to the next step. If the vehicle vibrates/shudder regardless of service brake operation, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for noise and vibration diagnosis in Groups 02, 03, 05, 09, 11, 19, and 22. 2. Drive the vehicle at a safe speed in area free of traffic. Lightly apply the parking brake. If the vehicle vibrates/shudder while the parking brake is applied, proceed to the next step. If the vehicle does not vibrate/shudder while the parking brake is applied, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for front brake vibration diagnosis in Group 05. 3. Raise the vehicle on a suitable hoist. NOTE: MAKE SURE THE PARKING BRAKE IS NOT APPLIED PRIOR TO LIFTING THE VEHICLE ON A HOIST. 4. Remove both right and left rear tire/wheel assemblies. 5. Remove both right and left rear brake drums. 6. Using a 100 - 125 mm (4-5 in.) micrometer or vernier caliper, measure the diameter of the brake drum pilot on the axle shaft (Figure 1). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 3997 7. If the brake drum pilot is less than 122.7 mm (4.830 in.) (Figure 2), perform the Repair Procedure. If the brake drum pilot is equal to or greater than 122.7 mm (4.830 in.), refer to the 1998 Ram Van Service Manual (Publication No. 81-370- 8107), pages 5-5 through 5-11 for information regarding brake system Diagnosis and Testing. Repair Procedure This bulletin involves installing revised axle shafts and if necessary brake linings and drums. 1. Clean all foreign material from the axle housing cover area. 2. Position a drain pan under the axle housing cover area. 3. Loosen housing cover bolts. Drain the lubricant from the housing and axle shaft tubes. Remove the housing cover. 4. Remove the original sealant from the housing and cover surfaces then, clean the cover surfaces with Mopar Brake parts Cleaner p/n 04549623. 5. Rotate the differential case so that the pinion mate gear shaft lock screw is accessible. Remove the lock screw and pinion mate gear shaft from the differential case (Figure 3). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 3998 6. Push the axle shaft inward and remove the axle shaft C-clip lock from the axle shaft (Figure 4.). 7. Remove axle shaft. Use care to prevent damage to the axle shaft bearing and seal, which will remain in the axle shaft tube. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 8. Inspect the axle shaft seal for leakage or damage and inspect the roller bearing contact surface on axle shaft for signs of brinelling, galling, and/or pitting. Replace the seal and/or bearing as necessary using p/n 04137314 for the seal and p/n 04117858 for the bearing. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 3-20 and 3-21 for Axle Seal And Bearing service. 9. Lubricate bearing bore and seal lip with gear lubricant p/n 05010320AA. Insert the new axle shaft p/n 041 17897AB through the seal and bearing, then engage the axle shaft splines into the side gear splines. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 10. Insert the C-clip lock onto the end of the axle shaft. Push axle shaft outward to seat the C-clip lock in the side gear. 11. Perform Steps 6 through 10 to the other axle shaft. 12. Insert pinion mate shaft into differential case and through thrust washers and pinion gears. 13. Align the hole in the shaft with the hole in the differential case. Apply Lock & Seal Adhesive p/n 04318031 to the threads of the pinion mate shaft lock screw and install the lock screw into the differential case. Tighten the screw to 11 Nm (8 ft. lbs). 14. Apply a bead of Mopar Silicone Sealant p/n 82300234 to the housing cover (Figure 5). The silicone sealant must be applied to all mating surfaces of the cover including around the cover bolt holes. NOTE: INSTALL THE COVER WITHIN FIVE MINUTES AFTER APPLYING THE SEALANT. 15. Install the cover and any identification tag. Tighten the cover attaching bolts to 44 Nm (33 ft. lbs.). 16. Fill the differential with 2.32 L (4.9 pts.) of Mopar 75W/90 Gear Lubricant p/n 0501 0320AA. 17. Inspect the brake linings on both sides of the vehicle. Replace the brake linings as necessary using p/n 05003999AA. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-21 through 5-22 for Rear Brake Shoes - 12 1/8 inch Removal and Installation. Anytime brake linings are replaced, new brake adjusting lever pins p/n 03492671 must be installed. 18. Measure brake drum diameter and runout. Brake drum diameter must be checked using an accurate brake drum micrometer. The maximum allowable diameter of the drum braking surface is indicated on the drum outer edge. Brake drum runout must be checked by mounting the drum onto a brake lathe and checking variation using a dial indicator. Variation in drum diameter should not exceed 0.076 mm (0.003 in.). Drum runout should not exceed 0.20 mm (0.008 in.) out of round. If the drum exceeds the variation/runout specification but does not exceed the maximum allowable diameter, resurface the brake drum. If the brake drum exceeds the maximum allowable diameter, replace the brake drum with p/n 5200951 9AC. If the brake drum is less than the maximum allowable variation/runout and the diameter of the drum is less than the maximum specification and there is not any major scoring in the drum, the drum can be reused. 19. Adjust brake shoes to brake drum using a brake gauge. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 3999 and 5-30 for information regarding proper brake shoe adjustment. 20. Install the brake drum onto the vehicle. 21. Install the tire and wheels onto the vehicle. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 22-8 and 22-9 for proper tire/wheel installation. 22. Adjust the park brake cable tension. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-30 and 5-31 for information regarding proper parking brake cable tension adjustment. 23. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application Technical Service Bulletin # 05-07-98 Date: 990201 Brakes - Vibration/Shudder on Application NO: 05-07-98 GROUP: Brakes DATE: Feb. 1, 1999 SUBJECT: Vehicle Vibrates/Shudders When Brakes Are Applied MODELS: 1998 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 250013500 RAM VANS EQUIPPED WITH THE 9.25 HD AXLE (SALES CODE DRG). SYMPTOM/CONDITION: Vehicle vibrates/shudders when the brakes are applied. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 03-20-01-94 Remove and Install Axle Shafts, Measure Drum Diameter and Runout, Adjust Rear Brakes, Adjust Parking Brake Brake 1.0 Hrs. Related Operations: NOTE: OPERATIONS INCLUDE REPLACING BRAKE DRUMS WHEN NECESSARY. 03-20-20-50 Replace Axle Bearing and Seal, Right Side 0.2 Hrs. 03-20-20-51 Replace Axle Bearing and Seal, Left Side 0.2 Hrs. 03-20-26-50 Replace Axle Seal, Right Side 0.1 Hrs. 03-20-26-51 Replace Axle Seal, Left Side 0.1 Hrs. 05-70-06-59 Replace Brake Shoes And Linings 0.4 Hrs. 05-20-26-51 Resurface One Brake Drum 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4005 05-20-26-52 Resurface Both Brake Drums 0.7 Hrs. FAILURE CODE: P8 - New Part Diagnosis 1. Drive the vehicle at a safe speed and apply the service brakes. If the vehicle does not vibrate/shudder until the brakes are applied, proceed to the next step. If the vehicle vibrates/shudder regardless of service brake operation, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for noise and vibration diagnosis in Groups 02, 03, 05, 09, 11, 19, and 22. 2. Drive the vehicle at a safe speed in area free of traffic. Lightly apply the parking brake. If the vehicle vibrates/shudder while the parking brake is applied, proceed to the next step. If the vehicle does not vibrate/shudder while the parking brake is applied, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for front brake vibration diagnosis in Group 05. 3. Raise the vehicle on a suitable hoist. NOTE: MAKE SURE THE PARKING BRAKE IS NOT APPLIED PRIOR TO LIFTING THE VEHICLE ON A HOIST. 4. Remove both right and left rear tire/wheel assemblies. 5. Remove both right and left rear brake drums. 6. Using a 100 - 125 mm (4-5 in.) micrometer or vernier caliper, measure the diameter of the brake drum pilot on the axle shaft (Figure 1). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4006 7. If the brake drum pilot is less than 122.7 mm (4.830 in.) (Figure 2), perform the Repair Procedure. If the brake drum pilot is equal to or greater than 122.7 mm (4.830 in.), refer to the 1998 Ram Van Service Manual (Publication No. 81-370- 8107), pages 5-5 through 5-11 for information regarding brake system Diagnosis and Testing. Repair Procedure This bulletin involves installing revised axle shafts and if necessary brake linings and drums. 1. Clean all foreign material from the axle housing cover area. 2. Position a drain pan under the axle housing cover area. 3. Loosen housing cover bolts. Drain the lubricant from the housing and axle shaft tubes. Remove the housing cover. 4. Remove the original sealant from the housing and cover surfaces then, clean the cover surfaces with Mopar Brake parts Cleaner p/n 04549623. 5. Rotate the differential case so that the pinion mate gear shaft lock screw is accessible. Remove the lock screw and pinion mate gear shaft from the differential case (Figure 3). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4007 6. Push the axle shaft inward and remove the axle shaft C-clip lock from the axle shaft (Figure 4.). 7. Remove axle shaft. Use care to prevent damage to the axle shaft bearing and seal, which will remain in the axle shaft tube. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 8. Inspect the axle shaft seal for leakage or damage and inspect the roller bearing contact surface on axle shaft for signs of brinelling, galling, and/or pitting. Replace the seal and/or bearing as necessary using p/n 04137314 for the seal and p/n 04117858 for the bearing. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 3-20 and 3-21 for Axle Seal And Bearing service. 9. Lubricate bearing bore and seal lip with gear lubricant p/n 05010320AA. Insert the new axle shaft p/n 041 17897AB through the seal and bearing, then engage the axle shaft splines into the side gear splines. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 10. Insert the C-clip lock onto the end of the axle shaft. Push axle shaft outward to seat the C-clip lock in the side gear. 11. Perform Steps 6 through 10 to the other axle shaft. 12. Insert pinion mate shaft into differential case and through thrust washers and pinion gears. 13. Align the hole in the shaft with the hole in the differential case. Apply Lock & Seal Adhesive p/n 04318031 to the threads of the pinion mate shaft lock screw and install the lock screw into the differential case. Tighten the screw to 11 Nm (8 ft. lbs). 14. Apply a bead of Mopar Silicone Sealant p/n 82300234 to the housing cover (Figure 5). The silicone sealant must be applied to all mating surfaces of the cover including around the cover bolt holes. NOTE: INSTALL THE COVER WITHIN FIVE MINUTES AFTER APPLYING THE SEALANT. 15. Install the cover and any identification tag. Tighten the cover attaching bolts to 44 Nm (33 ft. lbs.). 16. Fill the differential with 2.32 L (4.9 pts.) of Mopar 75W/90 Gear Lubricant p/n 0501 0320AA. 17. Inspect the brake linings on both sides of the vehicle. Replace the brake linings as necessary using p/n 05003999AA. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-21 through 5-22 for Rear Brake Shoes - 12 1/8 inch Removal and Installation. Anytime brake linings are replaced, new brake adjusting lever pins p/n 03492671 must be installed. 18. Measure brake drum diameter and runout. Brake drum diameter must be checked using an accurate brake drum micrometer. The maximum allowable diameter of the drum braking surface is indicated on the drum outer edge. Brake drum runout must be checked by mounting the drum onto a brake lathe and checking variation using a dial indicator. Variation in drum diameter should not exceed 0.076 mm (0.003 in.). Drum runout should not exceed 0.20 mm (0.008 in.) out of round. If the drum exceeds the variation/runout specification but does not exceed the maximum allowable diameter, resurface the brake drum. If the brake drum exceeds the maximum allowable diameter, replace the brake drum with p/n 5200951 9AC. If the brake drum is less than the maximum allowable variation/runout and the diameter of the drum is less than the maximum specification and there is not any major scoring in the drum, the drum can be reused. 19. Adjust brake shoes to brake drum using a brake gauge. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4008 and 5-30 for information regarding proper brake shoe adjustment. 20. Install the brake drum onto the vehicle. 21. Install the tire and wheels onto the vehicle. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 22-8 and 22-9 for proper tire/wheel installation. 22. Adjust the park brake cable tension. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-30 and 5-31 for information regarding proper parking brake cable tension adjustment. 23. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > 8-1/4 and 9-1/4 Axle Axle Shaft: Service and Repair 8-1/4 and 9-1/4 Axle REMOVAL 1. Raise and support vehicle. Ensure that the transmission is in neutral. 2. Remove wheel and tire assembly. 3. Remove brake drum. Refer to Brakes, for proper procedure. 4. Clean all foreign material from housing cover area. 5. Loosen housing cover bolts. Drain lubricant from the housing and axle shaft tubes. Remove housing cover. Mate Shaft Lock Screw 6. Rotate differential case so that pinion mate gear shaft lock screw is accessible. Remove lock screw and pinion mate gear shaft from differential case. Axle Shaft C-Clip Lock 7. Push axle shaft inward and remove axle shaft C-clip lock from the axle shaft. 8. Remove axle shaft. Use care to prevent damage to axle shaft bearing and seal, which will remain in axle shaft tube. 9. Inspect axle shaft seal for leakage or damage. 10. Inspect roller bearing contact surface on axle shaft for signs of brinelling, galling and pitting. If any of these conditions exist, the axle shaft and/or bearing and seal must be replaced. INSTALLATION 1. Lubricate bearing bore and seal lip with gear lubricant. Insert axle shaft through seal, bearing, and engage it into side gear splines. NOTE: Use care to prevent shaft splines from damaging axle shaft seal lip. 2. Insert C-clip lock in end of axle shaft. Push axle shaft outward to seat C-clip lock in side gear. 3. Insert pinion mate shaft into differential case and through thrust washers and pinion gears. 4. Align hole in shaft with hole in the differential case and install lock screw with Loctite(r) on the threads. Tighten lock screw to 11 Nm (8 ft. lbs.) torque. 5. Install cover and add fluid. Refer to Lubricant Change procedure in this section for procedure and lubricant requirements. 6. Install brake drum. Refer to Brakes, for proper procedures. 7. Install wheel and tire. 8. Lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > 8-1/4 and 9-1/4 Axle > Page 4011 Axle Shaft: Service and Repair Rear Axle - 248RBI CAUTION: RAISE BOTH REAR WHEELS OFF THE SURFACE WHENEVER A REAR AXLE IS BEING SERVICED. REMOVAL 1. Remove the axle shaft flange bolts. 2. Slide the axle shaft out from the axle tube. INSTALLATION 1. Clean the gasket contact surface area on the flange with an appropriate solvent. Install a new flange gasket and slide the axle shaft into the tube. 2. Install the bolts and tighten to 122 Nm (90 ft. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application Technical Service Bulletin # 05-07-98 Date: 990201 Brakes - Vibration/Shudder on Application NO: 05-07-98 GROUP: Brakes DATE: Feb. 1, 1999 SUBJECT: Vehicle Vibrates/Shudders When Brakes Are Applied MODELS: 1998 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 250013500 RAM VANS EQUIPPED WITH THE 9.25 HD AXLE (SALES CODE DRG). SYMPTOM/CONDITION: Vehicle vibrates/shudders when the brakes are applied. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 03-20-01-94 Remove and Install Axle Shafts, Measure Drum Diameter and Runout, Adjust Rear Brakes, Adjust Parking Brake Brake 1.0 Hrs. Related Operations: NOTE: OPERATIONS INCLUDE REPLACING BRAKE DRUMS WHEN NECESSARY. 03-20-20-50 Replace Axle Bearing and Seal, Right Side 0.2 Hrs. 03-20-20-51 Replace Axle Bearing and Seal, Left Side 0.2 Hrs. 03-20-26-50 Replace Axle Seal, Right Side 0.1 Hrs. 03-20-26-51 Replace Axle Seal, Left Side 0.1 Hrs. 05-70-06-59 Replace Brake Shoes And Linings 0.4 Hrs. 05-20-26-51 Resurface One Brake Drum 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4020 05-20-26-52 Resurface Both Brake Drums 0.7 Hrs. FAILURE CODE: P8 - New Part Diagnosis 1. Drive the vehicle at a safe speed and apply the service brakes. If the vehicle does not vibrate/shudder until the brakes are applied, proceed to the next step. If the vehicle vibrates/shudder regardless of service brake operation, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for noise and vibration diagnosis in Groups 02, 03, 05, 09, 11, 19, and 22. 2. Drive the vehicle at a safe speed in area free of traffic. Lightly apply the parking brake. If the vehicle vibrates/shudder while the parking brake is applied, proceed to the next step. If the vehicle does not vibrate/shudder while the parking brake is applied, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for front brake vibration diagnosis in Group 05. 3. Raise the vehicle on a suitable hoist. NOTE: MAKE SURE THE PARKING BRAKE IS NOT APPLIED PRIOR TO LIFTING THE VEHICLE ON A HOIST. 4. Remove both right and left rear tire/wheel assemblies. 5. Remove both right and left rear brake drums. 6. Using a 100 - 125 mm (4-5 in.) micrometer or vernier caliper, measure the diameter of the brake drum pilot on the axle shaft (Figure 1). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4021 7. If the brake drum pilot is less than 122.7 mm (4.830 in.) (Figure 2), perform the Repair Procedure. If the brake drum pilot is equal to or greater than 122.7 mm (4.830 in.), refer to the 1998 Ram Van Service Manual (Publication No. 81-370- 8107), pages 5-5 through 5-11 for information regarding brake system Diagnosis and Testing. Repair Procedure This bulletin involves installing revised axle shafts and if necessary brake linings and drums. 1. Clean all foreign material from the axle housing cover area. 2. Position a drain pan under the axle housing cover area. 3. Loosen housing cover bolts. Drain the lubricant from the housing and axle shaft tubes. Remove the housing cover. 4. Remove the original sealant from the housing and cover surfaces then, clean the cover surfaces with Mopar Brake parts Cleaner p/n 04549623. 5. Rotate the differential case so that the pinion mate gear shaft lock screw is accessible. Remove the lock screw and pinion mate gear shaft from the differential case (Figure 3). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4022 6. Push the axle shaft inward and remove the axle shaft C-clip lock from the axle shaft (Figure 4.). 7. Remove axle shaft. Use care to prevent damage to the axle shaft bearing and seal, which will remain in the axle shaft tube. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 8. Inspect the axle shaft seal for leakage or damage and inspect the roller bearing contact surface on axle shaft for signs of brinelling, galling, and/or pitting. Replace the seal and/or bearing as necessary using p/n 04137314 for the seal and p/n 04117858 for the bearing. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 3-20 and 3-21 for Axle Seal And Bearing service. 9. Lubricate bearing bore and seal lip with gear lubricant p/n 05010320AA. Insert the new axle shaft p/n 041 17897AB through the seal and bearing, then engage the axle shaft splines into the side gear splines. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 10. Insert the C-clip lock onto the end of the axle shaft. Push axle shaft outward to seat the C-clip lock in the side gear. 11. Perform Steps 6 through 10 to the other axle shaft. 12. Insert pinion mate shaft into differential case and through thrust washers and pinion gears. 13. Align the hole in the shaft with the hole in the differential case. Apply Lock & Seal Adhesive p/n 04318031 to the threads of the pinion mate shaft lock screw and install the lock screw into the differential case. Tighten the screw to 11 Nm (8 ft. lbs). 14. Apply a bead of Mopar Silicone Sealant p/n 82300234 to the housing cover (Figure 5). The silicone sealant must be applied to all mating surfaces of the cover including around the cover bolt holes. NOTE: INSTALL THE COVER WITHIN FIVE MINUTES AFTER APPLYING THE SEALANT. 15. Install the cover and any identification tag. Tighten the cover attaching bolts to 44 Nm (33 ft. lbs.). 16. Fill the differential with 2.32 L (4.9 pts.) of Mopar 75W/90 Gear Lubricant p/n 0501 0320AA. 17. Inspect the brake linings on both sides of the vehicle. Replace the brake linings as necessary using p/n 05003999AA. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-21 through 5-22 for Rear Brake Shoes - 12 1/8 inch Removal and Installation. Anytime brake linings are replaced, new brake adjusting lever pins p/n 03492671 must be installed. 18. Measure brake drum diameter and runout. Brake drum diameter must be checked using an accurate brake drum micrometer. The maximum allowable diameter of the drum braking surface is indicated on the drum outer edge. Brake drum runout must be checked by mounting the drum onto a brake lathe and checking variation using a dial indicator. Variation in drum diameter should not exceed 0.076 mm (0.003 in.). Drum runout should not exceed 0.20 mm (0.008 in.) out of round. If the drum exceeds the variation/runout specification but does not exceed the maximum allowable diameter, resurface the brake drum. If the brake drum exceeds the maximum allowable diameter, replace the brake drum with p/n 5200951 9AC. If the brake drum is less than the maximum allowable variation/runout and the diameter of the drum is less than the maximum specification and there is not any major scoring in the drum, the drum can be reused. 19. Adjust brake shoes to brake drum using a brake gauge. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4023 and 5-30 for information regarding proper brake shoe adjustment. 20. Install the brake drum onto the vehicle. 21. Install the tire and wheels onto the vehicle. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 22-8 and 22-9 for proper tire/wheel installation. 22. Adjust the park brake cable tension. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-30 and 5-31 for information regarding proper parking brake cable tension adjustment. 23. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application Technical Service Bulletin # 05-07-98 Date: 990201 Brakes - Vibration/Shudder on Application NO: 05-07-98 GROUP: Brakes DATE: Feb. 1, 1999 SUBJECT: Vehicle Vibrates/Shudders When Brakes Are Applied MODELS: 1998 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 250013500 RAM VANS EQUIPPED WITH THE 9.25 HD AXLE (SALES CODE DRG). SYMPTOM/CONDITION: Vehicle vibrates/shudders when the brakes are applied. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 03-20-01-94 Remove and Install Axle Shafts, Measure Drum Diameter and Runout, Adjust Rear Brakes, Adjust Parking Brake Brake 1.0 Hrs. Related Operations: NOTE: OPERATIONS INCLUDE REPLACING BRAKE DRUMS WHEN NECESSARY. 03-20-20-50 Replace Axle Bearing and Seal, Right Side 0.2 Hrs. 03-20-20-51 Replace Axle Bearing and Seal, Left Side 0.2 Hrs. 03-20-26-50 Replace Axle Seal, Right Side 0.1 Hrs. 03-20-26-51 Replace Axle Seal, Left Side 0.1 Hrs. 05-70-06-59 Replace Brake Shoes And Linings 0.4 Hrs. 05-20-26-51 Resurface One Brake Drum 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4029 05-20-26-52 Resurface Both Brake Drums 0.7 Hrs. FAILURE CODE: P8 - New Part Diagnosis 1. Drive the vehicle at a safe speed and apply the service brakes. If the vehicle does not vibrate/shudder until the brakes are applied, proceed to the next step. If the vehicle vibrates/shudder regardless of service brake operation, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for noise and vibration diagnosis in Groups 02, 03, 05, 09, 11, 19, and 22. 2. Drive the vehicle at a safe speed in area free of traffic. Lightly apply the parking brake. If the vehicle vibrates/shudder while the parking brake is applied, proceed to the next step. If the vehicle does not vibrate/shudder while the parking brake is applied, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for front brake vibration diagnosis in Group 05. 3. Raise the vehicle on a suitable hoist. NOTE: MAKE SURE THE PARKING BRAKE IS NOT APPLIED PRIOR TO LIFTING THE VEHICLE ON A HOIST. 4. Remove both right and left rear tire/wheel assemblies. 5. Remove both right and left rear brake drums. 6. Using a 100 - 125 mm (4-5 in.) micrometer or vernier caliper, measure the diameter of the brake drum pilot on the axle shaft (Figure 1). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4030 7. If the brake drum pilot is less than 122.7 mm (4.830 in.) (Figure 2), perform the Repair Procedure. If the brake drum pilot is equal to or greater than 122.7 mm (4.830 in.), refer to the 1998 Ram Van Service Manual (Publication No. 81-370- 8107), pages 5-5 through 5-11 for information regarding brake system Diagnosis and Testing. Repair Procedure This bulletin involves installing revised axle shafts and if necessary brake linings and drums. 1. Clean all foreign material from the axle housing cover area. 2. Position a drain pan under the axle housing cover area. 3. Loosen housing cover bolts. Drain the lubricant from the housing and axle shaft tubes. Remove the housing cover. 4. Remove the original sealant from the housing and cover surfaces then, clean the cover surfaces with Mopar Brake parts Cleaner p/n 04549623. 5. Rotate the differential case so that the pinion mate gear shaft lock screw is accessible. Remove the lock screw and pinion mate gear shaft from the differential case (Figure 3). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4031 6. Push the axle shaft inward and remove the axle shaft C-clip lock from the axle shaft (Figure 4.). 7. Remove axle shaft. Use care to prevent damage to the axle shaft bearing and seal, which will remain in the axle shaft tube. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 8. Inspect the axle shaft seal for leakage or damage and inspect the roller bearing contact surface on axle shaft for signs of brinelling, galling, and/or pitting. Replace the seal and/or bearing as necessary using p/n 04137314 for the seal and p/n 04117858 for the bearing. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 3-20 and 3-21 for Axle Seal And Bearing service. 9. Lubricate bearing bore and seal lip with gear lubricant p/n 05010320AA. Insert the new axle shaft p/n 041 17897AB through the seal and bearing, then engage the axle shaft splines into the side gear splines. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 10. Insert the C-clip lock onto the end of the axle shaft. Push axle shaft outward to seat the C-clip lock in the side gear. 11. Perform Steps 6 through 10 to the other axle shaft. 12. Insert pinion mate shaft into differential case and through thrust washers and pinion gears. 13. Align the hole in the shaft with the hole in the differential case. Apply Lock & Seal Adhesive p/n 04318031 to the threads of the pinion mate shaft lock screw and install the lock screw into the differential case. Tighten the screw to 11 Nm (8 ft. lbs). 14. Apply a bead of Mopar Silicone Sealant p/n 82300234 to the housing cover (Figure 5). The silicone sealant must be applied to all mating surfaces of the cover including around the cover bolt holes. NOTE: INSTALL THE COVER WITHIN FIVE MINUTES AFTER APPLYING THE SEALANT. 15. Install the cover and any identification tag. Tighten the cover attaching bolts to 44 Nm (33 ft. lbs.). 16. Fill the differential with 2.32 L (4.9 pts.) of Mopar 75W/90 Gear Lubricant p/n 0501 0320AA. 17. Inspect the brake linings on both sides of the vehicle. Replace the brake linings as necessary using p/n 05003999AA. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-21 through 5-22 for Rear Brake Shoes - 12 1/8 inch Removal and Installation. Anytime brake linings are replaced, new brake adjusting lever pins p/n 03492671 must be installed. 18. Measure brake drum diameter and runout. Brake drum diameter must be checked using an accurate brake drum micrometer. The maximum allowable diameter of the drum braking surface is indicated on the drum outer edge. Brake drum runout must be checked by mounting the drum onto a brake lathe and checking variation using a dial indicator. Variation in drum diameter should not exceed 0.076 mm (0.003 in.). Drum runout should not exceed 0.20 mm (0.008 in.) out of round. If the drum exceeds the variation/runout specification but does not exceed the maximum allowable diameter, resurface the brake drum. If the brake drum exceeds the maximum allowable diameter, replace the brake drum with p/n 5200951 9AC. If the brake drum is less than the maximum allowable variation/runout and the diameter of the drum is less than the maximum specification and there is not any major scoring in the drum, the drum can be reused. 19. Adjust brake shoes to brake drum using a brake gauge. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4032 and 5-30 for information regarding proper brake shoe adjustment. 20. Install the brake drum onto the vehicle. 21. Install the tire and wheels onto the vehicle. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 22-8 and 22-9 for proper tire/wheel installation. 22. Adjust the park brake cable tension. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-30 and 5-31 for information regarding proper parking brake cable tension adjustment. 23. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4033 Seals and Gaskets: By Symptom Technical Service Bulletin # 05-07-98 Date: 990201 Brakes - Vibration/Shudder on Application NO: 05-07-98 GROUP: Brakes DATE: Feb. 1, 1999 SUBJECT: Vehicle Vibrates/Shudders When Brakes Are Applied MODELS: 1998 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 250013500 RAM VANS EQUIPPED WITH THE 9.25 HD AXLE (SALES CODE DRG). SYMPTOM/CONDITION: Vehicle vibrates/shudders when the brakes are applied. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 03-20-01-94 Remove and Install Axle Shafts, Measure Drum Diameter and Runout, Adjust Rear Brakes, Adjust Parking Brake Brake 1.0 Hrs. Related Operations: NOTE: OPERATIONS INCLUDE REPLACING BRAKE DRUMS WHEN NECESSARY. 03-20-20-50 Replace Axle Bearing and Seal, Right Side 0.2 Hrs. 03-20-20-51 Replace Axle Bearing and Seal, Left Side 0.2 Hrs. 03-20-26-50 Replace Axle Seal, Right Side 0.1 Hrs. 03-20-26-51 Replace Axle Seal, Left Side 0.1 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4034 05-70-06-59 Replace Brake Shoes And Linings 0.4 Hrs. 05-20-26-51 Resurface One Brake Drum 0.4 Hrs. 05-20-26-52 Resurface Both Brake Drums 0.7 Hrs. FAILURE CODE: P8 - New Part Diagnosis 1. Drive the vehicle at a safe speed and apply the service brakes. If the vehicle does not vibrate/shudder until the brakes are applied, proceed to the next step. If the vehicle vibrates/shudder regardless of service brake operation, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for noise and vibration diagnosis in Groups 02, 03, 05, 09, 11, 19, and 22. 2. Drive the vehicle at a safe speed in area free of traffic. Lightly apply the parking brake. If the vehicle vibrates/shudder while the parking brake is applied, proceed to the next step. If the vehicle does not vibrate/shudder while the parking brake is applied, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for front brake vibration diagnosis in Group 05. 3. Raise the vehicle on a suitable hoist. NOTE: MAKE SURE THE PARKING BRAKE IS NOT APPLIED PRIOR TO LIFTING THE VEHICLE ON A HOIST. 4. Remove both right and left rear tire/wheel assemblies. 5. Remove both right and left rear brake drums. 6. Using a 100 - 125 mm (4-5 in.) micrometer or vernier caliper, measure the diameter of the brake drum pilot on the axle shaft (Figure 1). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4035 7. If the brake drum pilot is less than 122.7 mm (4.830 in.) (Figure 2), perform the Repair Procedure. If the brake drum pilot is equal to or greater than 122.7 mm (4.830 in.), refer to the 1998 Ram Van Service Manual (Publication No. 81-370- 8107), pages 5-5 through 5-11 for information regarding brake system Diagnosis and Testing. Repair Procedure This bulletin involves installing revised axle shafts and if necessary brake linings and drums. 1. Clean all foreign material from the axle housing cover area. 2. Position a drain pan under the axle housing cover area. 3. Loosen housing cover bolts. Drain the lubricant from the housing and axle shaft tubes. Remove the housing cover. 4. Remove the original sealant from the housing and cover surfaces then, clean the cover surfaces with Mopar Brake parts Cleaner p/n 04549623. 5. Rotate the differential case so that the pinion mate gear shaft lock screw is accessible. Remove the lock screw and pinion mate gear shaft from the differential case (Figure 3). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4036 6. Push the axle shaft inward and remove the axle shaft C-clip lock from the axle shaft (Figure 4.). 7. Remove axle shaft. Use care to prevent damage to the axle shaft bearing and seal, which will remain in the axle shaft tube. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 8. Inspect the axle shaft seal for leakage or damage and inspect the roller bearing contact surface on axle shaft for signs of brinelling, galling, and/or pitting. Replace the seal and/or bearing as necessary using p/n 04137314 for the seal and p/n 04117858 for the bearing. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 3-20 and 3-21 for Axle Seal And Bearing service. 9. Lubricate bearing bore and seal lip with gear lubricant p/n 05010320AA. Insert the new axle shaft p/n 041 17897AB through the seal and bearing, then engage the axle shaft splines into the side gear splines. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 10. Insert the C-clip lock onto the end of the axle shaft. Push axle shaft outward to seat the C-clip lock in the side gear. 11. Perform Steps 6 through 10 to the other axle shaft. 12. Insert pinion mate shaft into differential case and through thrust washers and pinion gears. 13. Align the hole in the shaft with the hole in the differential case. Apply Lock & Seal Adhesive p/n 04318031 to the threads of the pinion mate shaft lock screw and install the lock screw into the differential case. Tighten the screw to 11 Nm (8 ft. lbs). 14. Apply a bead of Mopar Silicone Sealant p/n 82300234 to the housing cover (Figure 5). The silicone sealant must be applied to all mating surfaces of the cover including around the cover bolt holes. NOTE: INSTALL THE COVER WITHIN FIVE MINUTES AFTER APPLYING THE SEALANT. 15. Install the cover and any identification tag. Tighten the cover attaching bolts to 44 Nm (33 ft. lbs.). 16. Fill the differential with 2.32 L (4.9 pts.) of Mopar 75W/90 Gear Lubricant p/n 0501 0320AA. 17. Inspect the brake linings on both sides of the vehicle. Replace the brake linings as necessary using p/n 05003999AA. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-21 through 5-22 for Rear Brake Shoes - 12 1/8 inch Removal and Installation. Anytime brake linings are replaced, new brake adjusting lever pins p/n 03492671 must be installed. 18. Measure brake drum diameter and runout. Brake drum diameter must be checked using an accurate brake drum micrometer. The maximum allowable diameter of the drum braking surface is indicated on the drum outer edge. Brake drum runout must be checked by mounting the drum onto a brake lathe and checking variation using a dial indicator. Variation in drum diameter should not exceed 0.076 mm (0.003 in.). Drum runout should not exceed 0.20 mm (0.008 in.) out of round. If the drum exceeds the variation/runout specification but does not exceed the maximum allowable diameter, resurface the brake drum. If the brake drum exceeds the maximum allowable diameter, replace the brake drum with p/n 5200951 9AC. If the brake drum is less than the maximum allowable variation/runout and the diameter of the drum is less than the maximum specification and there is not any major scoring in the drum, the drum can be reused. 19. Adjust brake shoes to brake drum using a brake gauge. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4037 and 5-30 for information regarding proper brake shoe adjustment. 20. Install the brake drum onto the vehicle. 21. Install the tire and wheels onto the vehicle. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 22-8 and 22-9 for proper tire/wheel installation. 22. Adjust the park brake cable tension. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-30 and 5-31 for information regarding proper parking brake cable tension adjustment. 23. Lower the vehicle. Technical Service Bulletin # 05-07-98 Date: 990201 Brakes - Vibration/Shudder on Application NO: 05-07-98 GROUP: Brakes DATE: Feb. 1, 1999 SUBJECT: Vehicle Vibrates/Shudders When Brakes Are Applied MODELS: 1998 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 250013500 RAM VANS EQUIPPED WITH THE 9.25 HD AXLE (SALES CODE DRG). SYMPTOM/CONDITION: Vehicle vibrates/shudders when the brakes are applied. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 03-20-01-94 Remove and Install Axle Shafts, Measure Drum Diameter and Runout, Adjust Rear Brakes, Adjust Parking Brake Brake 1.0 Hrs. Related Operations: NOTE: OPERATIONS INCLUDE REPLACING BRAKE DRUMS WHEN NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4038 03-20-20-50 Replace Axle Bearing and Seal, Right Side 0.2 Hrs. 03-20-20-51 Replace Axle Bearing and Seal, Left Side 0.2 Hrs. 03-20-26-50 Replace Axle Seal, Right Side 0.1 Hrs. 03-20-26-51 Replace Axle Seal, Left Side 0.1 Hrs. 05-70-06-59 Replace Brake Shoes And Linings 0.4 Hrs. 05-20-26-51 Resurface One Brake Drum 0.4 Hrs. 05-20-26-52 Resurface Both Brake Drums 0.7 Hrs. FAILURE CODE: P8 - New Part Diagnosis 1. Drive the vehicle at a safe speed and apply the service brakes. If the vehicle does not vibrate/shudder until the brakes are applied, proceed to the next step. If the vehicle vibrates/shudder regardless of service brake operation, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for noise and vibration diagnosis in Groups 02, 03, 05, 09, 11, 19, and 22. 2. Drive the vehicle at a safe speed in area free of traffic. Lightly apply the parking brake. If the vehicle vibrates/shudder while the parking brake is applied, proceed to the next step. If the vehicle does not vibrate/shudder while the parking brake is applied, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for front brake vibration diagnosis in Group 05. 3. Raise the vehicle on a suitable hoist. NOTE: MAKE SURE THE PARKING BRAKE IS NOT APPLIED PRIOR TO LIFTING THE VEHICLE ON A HOIST. 4. Remove both right and left rear tire/wheel assemblies. 5. Remove both right and left rear brake drums. 6. Using a 100 - 125 mm (4-5 in.) micrometer or vernier caliper, measure the diameter of the brake drum pilot on the axle shaft (Figure 1). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4039 7. If the brake drum pilot is less than 122.7 mm (4.830 in.) (Figure 2), perform the Repair Procedure. If the brake drum pilot is equal to or greater than 122.7 mm (4.830 in.), refer to the 1998 Ram Van Service Manual (Publication No. 81-370- 8107), pages 5-5 through 5-11 for information regarding brake system Diagnosis and Testing. Repair Procedure This bulletin involves installing revised axle shafts and if necessary brake linings and drums. 1. Clean all foreign material from the axle housing cover area. 2. Position a drain pan under the axle housing cover area. 3. Loosen housing cover bolts. Drain the lubricant from the housing and axle shaft tubes. Remove the housing cover. 4. Remove the original sealant from the housing and cover surfaces then, clean the cover surfaces with Mopar Brake parts Cleaner p/n 04549623. 5. Rotate the differential case so that the pinion mate gear shaft lock screw is accessible. Remove the lock screw and pinion mate gear shaft from the differential case (Figure 3). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4040 6. Push the axle shaft inward and remove the axle shaft C-clip lock from the axle shaft (Figure 4.). 7. Remove axle shaft. Use care to prevent damage to the axle shaft bearing and seal, which will remain in the axle shaft tube. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 8. Inspect the axle shaft seal for leakage or damage and inspect the roller bearing contact surface on axle shaft for signs of brinelling, galling, and/or pitting. Replace the seal and/or bearing as necessary using p/n 04137314 for the seal and p/n 04117858 for the bearing. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 3-20 and 3-21 for Axle Seal And Bearing service. 9. Lubricate bearing bore and seal lip with gear lubricant p/n 05010320AA. Insert the new axle shaft p/n 041 17897AB through the seal and bearing, then engage the axle shaft splines into the side gear splines. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 10. Insert the C-clip lock onto the end of the axle shaft. Push axle shaft outward to seat the C-clip lock in the side gear. 11. Perform Steps 6 through 10 to the other axle shaft. 12. Insert pinion mate shaft into differential case and through thrust washers and pinion gears. 13. Align the hole in the shaft with the hole in the differential case. Apply Lock & Seal Adhesive p/n 04318031 to the threads of the pinion mate shaft lock screw and install the lock screw into the differential case. Tighten the screw to 11 Nm (8 ft. lbs). 14. Apply a bead of Mopar Silicone Sealant p/n 82300234 to the housing cover (Figure 5). The silicone sealant must be applied to all mating surfaces of the cover including around the cover bolt holes. NOTE: INSTALL THE COVER WITHIN FIVE MINUTES AFTER APPLYING THE SEALANT. 15. Install the cover and any identification tag. Tighten the cover attaching bolts to 44 Nm (33 ft. lbs.). 16. Fill the differential with 2.32 L (4.9 pts.) of Mopar 75W/90 Gear Lubricant p/n 0501 0320AA. 17. Inspect the brake linings on both sides of the vehicle. Replace the brake linings as necessary using p/n 05003999AA. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-21 through 5-22 for Rear Brake Shoes - 12 1/8 inch Removal and Installation. Anytime brake linings are replaced, new brake adjusting lever pins p/n 03492671 must be installed. 18. Measure brake drum diameter and runout. Brake drum diameter must be checked using an accurate brake drum micrometer. The maximum allowable diameter of the drum braking surface is indicated on the drum outer edge. Brake drum runout must be checked by mounting the drum onto a brake lathe and checking variation using a dial indicator. Variation in drum diameter should not exceed 0.076 mm (0.003 in.). Drum runout should not exceed 0.20 mm (0.008 in.) out of round. If the drum exceeds the variation/runout specification but does not exceed the maximum allowable diameter, resurface the brake drum. If the brake drum exceeds the maximum allowable diameter, replace the brake drum with p/n 5200951 9AC. If the brake drum is less than the maximum allowable variation/runout and the diameter of the drum is less than the maximum specification and there is not any major scoring in the drum, the drum can be reused. 19. Adjust brake shoes to brake drum using a brake gauge. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4041 and 5-30 for information regarding proper brake shoe adjustment. 20. Install the brake drum onto the vehicle. 21. Install the tire and wheels onto the vehicle. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 22-8 and 22-9 for proper tire/wheel installation. 22. Adjust the park brake cable tension. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-30 and 5-31 for information regarding proper parking brake cable tension adjustment. 23. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle - 8 1/4 or 9 1/4 Light duty Seals and Gaskets: Service and Repair Rear Axle - 8 1/4 or 9 1/4 Light duty REMOVAL 1. Remove axle shaft. Axle Seal Removal 2. Remove axle shaft seal from the end of the axle tube with a small pry bar. NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. Axle Shaft Bearing Removal Tool 3. Remove the axle shaft bearing from the axle tube with Bearing Removal Tool Set 6310, using Adapter Foot 6310-9. INSTALLATION NOTE: Do not install the original axle shaft seal. Always install a new seal. 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle - 8 1/4 or 9 1/4 Light duty > Page 4044 Axle Shaft Seal And Bearing Installation 2. Install the axle shaft bearing with Installer C-4198 and Handle C-4171. Ensure that the bearing part number is against the installer. Verify that the bearing in installed straight and the tool fully contacts the axle tube when seating the bearing. 3. Install a new axle seal with Installer C-4076-B and Handle C-4735-1. When the tool contacts the axle tube, the seal is installed to the correct depth. 4. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 5. Install the axle shaft. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle - 8 1/4 or 9 1/4 Light duty > Page 4045 Seals and Gaskets: Service and Repair Rear Axle - 9 1/4 Heavy Duty REMOVAL 1. Remove axle shaft. Axle Seal Removal 2. Remove axle shaft seal from the end of the axle tube with a small pry bar. Axle Shaft Bearing Removal Tool 3. Remove the axle shaft bearing from the axle tube with Bearing Removal Tool C-4828. INSTALLATION NOTE: Do not install the original axle shaft seal. Always install a new seal. 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle - 8 1/4 or 9 1/4 Light duty > Page 4046 Axle Shaft Seal And Bearing Installation 2. Install the axle shaft bearing with Installer C-4826-1 and Handle C-4171. Ensure that the bearing part number is against the installer. Verify that the bearing in installed straight and the tool fully contacts the axle tube when seating the bearing. 3. Install a new axle seal with Installer C-4826-1, Adapter C-4826-2, and Handle C-4171. When the tool contacts the axle tube, the seal is installed to the correct depth. 4. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 5. Install the axle shaft. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 4055 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 4056 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 4057 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 4063 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 4064 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 4065 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised Wheel Bearing: All Technical Service Bulletins Steering Wander - Diagnosis and Correction Revised NUMBER: 19-07-00 GROUP: Steering DATE: September 22, 2000 SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering wander. MODELS: 1998-2001 (AB) Ram Van/Wagon SYMPTOM/CONDITION: Steering Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering wander can be created by a number of different conditions including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying extra added weight (e.g. tool boxes). ^ Steering and/or suspension components that are worn or damaged. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: UNDER CERTAIN ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. DIAGNOSIS: 1. Verify that the vehicle is not equipped with non-factory installed options or equipment that may cause the vehicle to wander such as heavy toolboxes or hardware that may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended may cause the vehicle to wander and should be replaced before continuing with the diagnosis. 3. Inflate all tires to the pressure specified in the Tire Inflation Pressure sheet (located in the glove box). NOTE: TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS BUT, ONLY IF THE VEHICLE IS AT CURB OR LIGHT LOAD CONDITIONS. 4. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without cross wind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Proceed to the next step if the vehicle exhibits a steering wander condition. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-3 OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, ETC.). 5. Raise the vehicle on an appropriate lift. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised > Page 4070 6. Secure a dial indicator to the lower control arm. Position the dial indicator so that the tip of the indicator contacts the inside face of the rotor (Figure 1). 7. Place your hands at the top and bottom of the tire/wheel assembly and push the tire/wheel assembly inboard (Figure 2). Zero the dial indicator. With your hands at the top and bottom of the tire/wheel assembly, pull the tire/wheel assembly outboard (Figure 3). Record the dial indicator reading. Perform this procedure on both front wheel bearings and proceed to the next step if the wheel bearing endplay exceeds 0.025 - 0.076 mm (0.001 - 0.003 in.). Proceed to Step 9 if wheel-bearing endplay on both front wheel bearings are within specifications. NOTE: WHEEL BEARING INSPECTION AND ADJUSTMENT IS ONLY REQUIRED ON WHEEL BEARINGS EXCEEDING 0.025 - 0.076 MM (0.001 - 0.003 IN.) ENDPLAY. 8. Remove the wheel bearing protective end cap, cotter pin, nut lock, nut, and washer from the spindle. Inspect the wheel bearings. If it is determined that wheel bearing replacement is necessary, refer to the appropriate Ram Van/Wagon Service Manual, Group 02, Wheel Bearings, for removal and installation information. Reinstall the wheel bearings, washer, and adjustment nut if the wheel bearings pass the inspection. 9. Using a torque wrench, tighten the wheel bearing adjustment nut to 54 N.m (40 ft. lbs.) while rotating the tire/wheel assembly. Stop the wheel from rotating and loosen the nut. Using the procedure identified in Steps 6 and 7 to measure endplay, adjust the front wheel bearing endplay until 0.025 - 0.076 mm (0.001 - 0.003 in.) endplay has been achieved. Install the nut lock and a new cotter pin. 10. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual. Any worn steering and/or suspension component must be replaced prior to performing an alignment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised > Page 4071 11. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the chart for proper alignment specifications. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised Wheel Bearing: All Technical Service Bulletins Steering Wander - Diagnosis and Correction Revised NUMBER: 19-07-00 GROUP: Steering DATE: September 22, 2000 SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering wander. MODELS: 1998-2001 (AB) Ram Van/Wagon SYMPTOM/CONDITION: Steering Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering wander can be created by a number of different conditions including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying extra added weight (e.g. tool boxes). ^ Steering and/or suspension components that are worn or damaged. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: UNDER CERTAIN ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. DIAGNOSIS: 1. Verify that the vehicle is not equipped with non-factory installed options or equipment that may cause the vehicle to wander such as heavy toolboxes or hardware that may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended may cause the vehicle to wander and should be replaced before continuing with the diagnosis. 3. Inflate all tires to the pressure specified in the Tire Inflation Pressure sheet (located in the glove box). NOTE: TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS BUT, ONLY IF THE VEHICLE IS AT CURB OR LIGHT LOAD CONDITIONS. 4. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without cross wind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Proceed to the next step if the vehicle exhibits a steering wander condition. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-3 OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, ETC.). 5. Raise the vehicle on an appropriate lift. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised > Page 4077 6. Secure a dial indicator to the lower control arm. Position the dial indicator so that the tip of the indicator contacts the inside face of the rotor (Figure 1). 7. Place your hands at the top and bottom of the tire/wheel assembly and push the tire/wheel assembly inboard (Figure 2). Zero the dial indicator. With your hands at the top and bottom of the tire/wheel assembly, pull the tire/wheel assembly outboard (Figure 3). Record the dial indicator reading. Perform this procedure on both front wheel bearings and proceed to the next step if the wheel bearing endplay exceeds 0.025 - 0.076 mm (0.001 - 0.003 in.). Proceed to Step 9 if wheel-bearing endplay on both front wheel bearings are within specifications. NOTE: WHEEL BEARING INSPECTION AND ADJUSTMENT IS ONLY REQUIRED ON WHEEL BEARINGS EXCEEDING 0.025 - 0.076 MM (0.001 - 0.003 IN.) ENDPLAY. 8. Remove the wheel bearing protective end cap, cotter pin, nut lock, nut, and washer from the spindle. Inspect the wheel bearings. If it is determined that wheel bearing replacement is necessary, refer to the appropriate Ram Van/Wagon Service Manual, Group 02, Wheel Bearings, for removal and installation information. Reinstall the wheel bearings, washer, and adjustment nut if the wheel bearings pass the inspection. 9. Using a torque wrench, tighten the wheel bearing adjustment nut to 54 N.m (40 ft. lbs.) while rotating the tire/wheel assembly. Stop the wheel from rotating and loosen the nut. Using the procedure identified in Steps 6 and 7 to measure endplay, adjust the front wheel bearing endplay until 0.025 - 0.076 mm (0.001 - 0.003 in.) endplay has been achieved. Install the nut lock and a new cotter pin. 10. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual. Any worn steering and/or suspension component must be replaced prior to performing an alignment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised > Page 4078 11. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the chart for proper alignment specifications. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Page 4079 Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front REMOVAL 1. Lock brake pedal in up position. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 4. Remove disc brake caliper. 5. Remove the dust cap, cotter pin, and remaining hub components from spindle. 6. Carefully slide the hub/rotor from spindle. CAUTION: Use care to prevent inner wheel bearing and seal from contacting spindle threads during removal). 7. Remove the seal and inner wheel bearing from the hub/rotor. Remove the inner bearing races from hub/rotor with a pin punch. INSTALLATION 1. Install the new bearing cup(s) with an appropriate installation tool. 2. Apply a coating of Mopar (R) Wheel Bearing Grease to inner surface area of hub. Install inner wheel bearing and new bearing seal. 3. Inspect bearing and seal contact surfaces on spindle for burrs and or roughness. 4. Remove all rough contact surfaces from spindle. Apply a coating of lubricant. CAUTION: Use care to prevent inner wheel bearing and seal from contacting spindle threads during installation. 5. Carefully slide the hub/rotor onto spindle. Install outer wheel bearing, washer and retaining nut. 6. Tighten the nut to 41 - 54 Nm (30 - 40 ft. lbs.) to preload bearing while rotating the hub/rotor. Stop hub/rotor and loosen nut to completely release bearing preload torque. Tighten the nut finger-tight and install the nut lock. Install a new cotter pin. 7. The adjustment (above) should have 0.254 - 0.0762 mm (0.001 - 0.003 inch) end play. 8. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. 9. Install disc brake caliper. 10. Install the wheel and tire assembly and lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4082 Wheel Bearing: Service and Repair Rear 8 1/4 and 9 1/4 Axles REMOVAL 1. Remove axle shaft. Axle Seal Removal 2. Remove axle shaft seal from the end of the axle tube with a small pry bar. NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. Axle Shaft Bearing Removal Tool 3. Remove the axle shaft bearing from the axle tube with Bearing Removal Tool Set 6310, using Adapter Foot 6310-9. INSTALLATION NOTE: Do not install the original axle shaft seal. Always install a new seal. 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4083 Axle Shaft Seal And Bearing Installation 2. Install the axle shaft bearing with Installer C-4198 and Handle C-4171. Ensure that the bearing part number is against the installer. Verify that the bearing in installed straight and the tool fully contacts the axle tube when seating the bearing. 3. Install a new axle seal with Installer C-4076-B and Handle C-4735-1. When the tool contacts the axle tube, the seal is installed to the correct depth. 4. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 5. Install the axle shaft. With 9 1/4 Axle REMOVAL 1. Remove axle shaft. Axle Seal Removal 2. Remove axle shaft seal from the end of the axle tube with a small pry bar. Axle Shaft Bearing Removal Tool Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4084 3. Remove the axle shaft bearing from the axle tube with Bearing Removal Tool C-4828. INSTALLATION NOTE: Do not install the original axle shaft seal. Always install a new seal. 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. Axle Shaft Seal And Bearing Installation 2. Install the axle shaft bearing with Installer C-4826-1 and Handle C-4171. Ensure that the bearing part number is against the installer. Verify that the bearing in installed straight and the tool fully contacts the axle tube when seating the bearing. 3. Install a new axle seal with Installer C-4826-1, Adapter C-4826-2, and Handle C-4171. When the tool contacts the axle tube, the seal is installed to the correct depth. 4. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 5. Install the axle shaft. 248 RBI Axle REMOVAL 1. Remove wheel and tire assembly. 2. Remove brake drum. 3. Remove the axle shaft. 4. Remove the lock wedge and adjustment nut. Use Socket DD-1241-JD to remove the adjustment nut. 5. Remove the hub assembly. The outer axle bearing will slide out as the hub is being removed. 6. Remove inner grease seal and discard. Use Installer 5064 and Handle C-4171 to drive grease seal and inner axle bearing from the hub. 7. Remove the bearing cups from the hub bore. Use a brass drift, or an appropriate removal tool, to tap out the cups. INSTALLATION 1. Thoroughly clean both axle bearings and interior of the hub with an appropriate cleaning solvent. 2. Install the bearing cups. Use Installer 8151 and Handle C-4171 to install the bearing cups. 3. Apply lubricant to surface area of the bearing cup. 4. Install the inner axle bearing in the hub. 5. Install a new bearing grease seal. Use Installer 8149 and Handle C-4171 to install the grease seal. 6. Inspect the bearing and seal contact surfaces on the axle tube spindle for burrs and/or roughness. Remove all the rough contact surfaces from the axle spindle. Apply a coating of multi-purpose NLGI, grade 2, EP-type lubricant to the axle. CAUTION: Use care to prevent the bearing grease seal from contacting the axle tube spindle threads during installation. Otherwise, the seal could be damaged. 7. Carefully slide the hub onto the axle. 8. Install the outer axle bearing. 9. Install the hub bearing adjustment nut. Use Socket DD-1241-JD to install the adjustment nut. 10. Tighten the adjustment nut to 163-190 Nm (120-140 ft. lbs.) while rotating the wheel. 11. Loosen the adjustment nut 1/8 of-a-turn to provide 0.001-inch to 0.010-inch wheel bearing end play. 12. Tap the locking wedge into the spindle keyway and adjustment nut. Try to ensure that the locking wedge is installed into a new position in the adjustment nut. 13. Install the axle shaft. 14. Install the brake drum. 15. Install the wheel and tire assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 03-07-98 > Dec > 98 > Axle - Noise/Whine Between 35 and 55 MPH Drive/Propeller Shaft: Customer Interest Axle - Noise/Whine Between 35 and 55 MPH NO: 03-07-98 GROUP: Axle And Propshafts DATE: Dec. 11, 1998 SUBJECT: Axle Noise/Whine Between 35 And 55 MPH MODELS: 1998 - 1999 (AB) Ram Van NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 9-1/4 OR DANA 60 (248RBI) AXLE BUILT PRIOR TO OCT. 1, 1998 (MDH1001XX). SYMPTOM/CONDITION: Some vehicles may exhibit axle noise in the 35 to 55 mile per hour range. DIAGNOSIS: Drive the vehicle on a smooth road and listen for axle noise in the 35 to 55 mile per hour range. Note if the noise is heard during drive or coast. The 9-1/4 axle noise may be heard during coast conditions and the Dana 60 (248RBI) may be heard during drive conditions. If noise is heard, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Adhesive (Grey) AR 05010320AA Lube, 75W90 Gear AR(1) 52105679AB Shaft, Prop (9-1/4 Axle) AR(1) 52105678AB Shaft, Prop (Dana 60/248 RBI) REPAIR PROCEDURE: This bulletin involves checking gearset backlash, gear pattern, and replacing the prop shaft with a new torsionally damped part. 1. Drain the axle lube and remove the axle cover. Following service manual procedures, check the gearset for backlash and gear pattern. If proper backlash and gear pattern is found, proceed with the remaining steps. If improper backlash or gear pattern is found, make adjustments following standard procedures. 2. Following service manual procedures, remove the prop shaft. 3. Install p/n 52105679AB (9-1/4) or 52105678AB (Dana 60/248RBI) into the vehicle. 4. Road test the vehicle to confirm that the noise is minimized or gone. 5. If the noise is still heard, further axle diagnosis and repair will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 16-30-01-99 1.0 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 03-07-98 > Dec > 98 > Axle - Noise/Whine Between 35 and 55 MPH Drive/Propeller Shaft: All Technical Service Bulletins Axle - Noise/Whine Between 35 and 55 MPH NO: 03-07-98 GROUP: Axle And Propshafts DATE: Dec. 11, 1998 SUBJECT: Axle Noise/Whine Between 35 And 55 MPH MODELS: 1998 - 1999 (AB) Ram Van NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 9-1/4 OR DANA 60 (248RBI) AXLE BUILT PRIOR TO OCT. 1, 1998 (MDH1001XX). SYMPTOM/CONDITION: Some vehicles may exhibit axle noise in the 35 to 55 mile per hour range. DIAGNOSIS: Drive the vehicle on a smooth road and listen for axle noise in the 35 to 55 mile per hour range. Note if the noise is heard during drive or coast. The 9-1/4 axle noise may be heard during coast conditions and the Dana 60 (248RBI) may be heard during drive conditions. If noise is heard, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Adhesive (Grey) AR 05010320AA Lube, 75W90 Gear AR(1) 52105679AB Shaft, Prop (9-1/4 Axle) AR(1) 52105678AB Shaft, Prop (Dana 60/248 RBI) REPAIR PROCEDURE: This bulletin involves checking gearset backlash, gear pattern, and replacing the prop shaft with a new torsionally damped part. 1. Drain the axle lube and remove the axle cover. Following service manual procedures, check the gearset for backlash and gear pattern. If proper backlash and gear pattern is found, proceed with the remaining steps. If improper backlash or gear pattern is found, make adjustments following standard procedures. 2. Following service manual procedures, remove the prop shaft. 3. Install p/n 52105679AB (9-1/4) or 52105678AB (Dana 60/248RBI) into the vehicle. 4. Road test the vehicle to confirm that the noise is minimized or gone. 5. If the noise is still heard, further axle diagnosis and repair will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 16-30-01-99 1.0 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures Drive/Propeller Shaft: Procedures PROPELLER SHAFT 1. Clean all universal joint bores with cleaning solvent and a wire brush. 2. Inspect the yokes for distortion, cracks, and worn bearing cap bores. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4101 Drive/Propeller Shaft: Removal and Replacement REMOVAL 1. Raise and support vehicle on safety stands. 2. Shift the transmission to the Neutral position. 3. Using a suitable marker, mark a line across the axle pinion yoke and the propeller shaft yoke for installation reference. 4. Remove the bolts holding the universal joint clamps to the pinion yoke. Rear Propeller Shaft 5. Slide the slip yoke off of the transmission output shaft and remove the propeller shaft. INSTALLATION 1. Slide the slip yoke onto the transmission output shaft. 2. Align the installation reference marks made on the propeller shaft and pinion yoke. 3. Position universal joint into pinion yoke. 4. Install the universal joint clamp and clamp bolts to the pinion yoke. Tighten bolts to 19 Nm (14 ft. lbs.). 5. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Replacement Universal Joint: Removal and Replacement UNIVERSAL JOINT REPLACEMENT Single cardan universal joint components are not serviceable. If worn or leaking, they must be replaced as a unit. REMOVAL Reference Marks On Yoke 1. Scribe reference marks on the propeller shaft yokes, axle yoke, and transmission yoke before removal or component service. This will ensure correct phasing and eliminate possible vibration. 2. Remove the propeller shaft. 3. Using a soft drift, tap the outside of the bearing assembly to loosen snap ring. Remove Snap Ring 4. Remove snap rings from both sides of yoke. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Replacement > Page 4106 Press Out Bearing 5. Set the yoke in an arbor press or vise with a large socket beneath it. If joint is a replacement with a lube fitting position the yoke with the lube fitting pointing up. Place a smaller socket on the upper bearing assembly and press it through to release the lower bearing assembly. 6. If the bearing assembly will not pull out by hand after pressing, tap the base of the lug near it to dislodge. Press Out Remaining Bearing 7. To remove the opposite bearing, turn the yoke over and straighten the cross in the open hole. Then carefully press the end of the cross until the remaining bearing can be removed. CAUTION: If the cross or bearing assembly are cocked when being pressed, the bearing assembly will score the walls of the yoke bore and ruin the yoke. INSTALLATION 1. Clean all the universal joint yoke bores with cleaning solvent and a wire brush. 2. Inspect the yokes for distortion, cracks and worn bearing assembly bores. 3. Apply Extreme Pressure (EP) N.L.G.I. Grade 1 or 2 grease to aid in installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Replacement > Page 4107 Install Cross In Yoke 4. If the replacement joint has a lube fitting position the cross in the yoke with the fitting pointing up. Install Bearing On Trunnion 5. Place a bearing assembly over the trunnion and align it with the cross hole. Keep the needle bearings upright in the bearing assembly. A needle roller lying at the bottom will prevent proper assembly. 6. Press the bearing assembly into the cross hole enough to install a snap ring. Install a snap ring. 7. Place opposite bearing assembly over the trunnion and align it with the cross hole. 8. Press the bearing assembly into the cross hole enough to install a snap ring. Install a snap ring. 9. Add grease to lube fitting, if equipped. 10. Install the propeller shaft. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Replacement > Page 4108 Universal Joint: Overhaul DISASSEMBLY Individual components of cardan universal joints are not serviceable. If worn or leaking, they must be replaced as an assembly. 1. Remove the propeller shaft. 2. Using a soft drift, tap the outside of the bearing cap to loosen snap-ring. Remove Snap-Ring 3. Remove snap-rings from both sides of yoke. 4. Set the yoke in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap positioned beneath the yoke. 5. Position the yoke with the grease fitting, if equipped, pointing up. Press Out Bearing 6. Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and press the cap through the yoke to release the lower bearing cap. 7. If the bearing cap will not pull out of the yoke by hand after pressing, tap the yoke ear near the bearing cap to dislodge the cap. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Replacement > Page 4109 Press Out Remaining Bearing 8. To remove the opposite bearing cap, turn the yoke over and straighten the cross in the open hole. Then, carefully press the end of the cross until the remaining bearing cap can be removed. CAUTION: If the cross or bearing cap are not straight during installation, the bearing cap will score the walls of the yoke bore and damage can occur. ASSEMBLY 1. Apply Extreme Pressure (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores to aid in installation. Install Cross In Yoke 2. Position the cross in the yoke with its lube fitting, if equipped, pointing up. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Replacement > Page 4110 Install Bearing On Trunnion 3. Place a bearing cap over the trunnion and align the cap with the yoke bore. Keep the needle bearings upright in the bearing cap. A needle bearing lying at the bottom of the cap will prevent proper assembly. 4. Press the bearing cap into the yoke bore enough to install a snap ring. 5. Install a snap ring. 6. Repeat Step 4 and Step 5 to install the opposite bearing cap. If the joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings. 7. Add grease to lube fitting, if equipped. 8. Install the propeller shaft Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications TORQUE SPECIFICATIONS Bolt, Driveplate-to-Crankshaft ............................................................................................................. .................................................... 75 Nm (55 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation SYSTEM OPERATION The overdrive-off indicator lamp gives the driver an indication that the automatic transmission overdrive has been locked out. The lamp is controlled by the Powertrain Control Module (PCM) on a hard wired circuit to instrument cluster. The PCM receives an input from the momentary overdrive lockout switch, which is located on the end of the automatic transmission gearshift selector lever. The PCM uses the overdrive lockout switch input, along with numerous other sensor inputs and its internal programming to decide whether the over-drive-off indicator lamp should be on or off. The PCM then turns the lamp on or off by controlling the ground path for the lamp control circuit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 4119 Overdrive Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative overdrive-off indicator lamp condition. If the overdrive-off indicator lamp comes on and stays on with the engine running, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) and the transmission control system circuits. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Unplug the gray PCM wire harness connector. Install a jumper wire between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. Connect the battery negative cable. Turn the ignition switch to the On position. The overdrive-off indicator lamp should light. Remove the jumper wire and the lamp should turn off. If OK, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) and the transmission control system circuits. If not OK, go to Step 5. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the instrument cluster. Check for continuity between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the short circuit as required. 5. Check for continuity between the overdrive lamp driver circuit cavities of the gray PCM wire harness connector and the instrument cluster wire harness connector (connector A). There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4130 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4131 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4137 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4138 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 4139 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4143 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4144 Transmission Control Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 4155 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 4161 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4165 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation TRANSMISSION SPEED SENSOR Transmission Output Speed Sensor The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The rear wheel speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations > Component Locations O/D Solenoid,TCC Solenoid,governor Pressure Sensor,governor Pressure Solenoid Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations > Component Locations > Page 4179 Solenoid Case Connector,park/neutral Position Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations > Page 4180 Transmission Solenoid Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 4189 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 4195 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 4203 Park/Neutral Position Switch Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 4204 Torque Convertor Clutch Solenoid Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation SYSTEM OPERATION The overdrive-off indicator lamp gives the driver an indication that the automatic transmission overdrive has been locked out. The lamp is controlled by the Powertrain Control Module (PCM) on a hard wired circuit to instrument cluster. The PCM receives an input from the momentary overdrive lockout switch, which is located on the end of the automatic transmission gearshift selector lever. The PCM uses the overdrive lockout switch input, along with numerous other sensor inputs and its internal programming to decide whether the over-drive-off indicator lamp should be on or off. The PCM then turns the lamp on or off by controlling the ground path for the lamp control circuit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 4210 Overdrive Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative overdrive-off indicator lamp condition. If the overdrive-off indicator lamp comes on and stays on with the engine running, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) and the transmission control system circuits. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Unplug the gray PCM wire harness connector. Install a jumper wire between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. Connect the battery negative cable. Turn the ignition switch to the On position. The overdrive-off indicator lamp should light. Remove the jumper wire and the lamp should turn off. If OK, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) and the transmission control system circuits. If not OK, go to Step 5. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the instrument cluster. Check for continuity between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the short circuit as required. 5. Check for continuity between the overdrive lamp driver circuit cavities of the gray PCM wire harness connector and the instrument cluster wire harness connector (connector A). There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4221 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4222 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4228 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4229 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 4230 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4234 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4235 Transmission Control Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 4246 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 4252 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4256 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation TRANSMISSION SPEED SENSOR Transmission Output Speed Sensor The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The rear wheel speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WD Switch > Component Information > Description and Operation 4WD Switch: Description and Operation Vehicles equipped with four wheel drive (4WD) have an indicator switch mounted on the front axle assembly. This switch is closed to ground when the transfer case is shifted to four wheel drive mode and the engine is running on some vehicles. While in four wheel drive, the front and rear axles will operate together. With this input, the CAB is able to modify its operation to allow for 4WD operation. Should a need for antilock operation occur while in four wheel drive, the CAB will extend the amount of allowable dump cycles. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > General Information ABS Light: Description and Operation General Information SYSTEM OPERATION The Anti-Lock Brake System (ABS)lamp gives an indication when the ABS system is faulty or inoperative. The lamp is controlled by the instrument cluster circuitry based upon messages received from the Controller Anti-lock Brake (CAB) on the Chrysler Collision Detection (CCD) data bus. The lamp is turned on by the CAB for about two seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the CAB turns the lamp on or off based upon the results of the ABS self-tests. The CAB continually monitors the ABS circuits and sensors to decide whether the system is in good operating condition. The CAB then sends the proper messages to the instrument cluster on the CCD data bus to turn the lamp on or off. If the CAB turns the lamp on after the bulb test, it indicates that the CAB has detected a system malfunction and/or that the ABS system has become inoperative. If only the amber ABS lamp is illuminated, and the red brake warning lamp remains off, the base brake system will operate normally. Each time the instrument cluster circuitry receives a lamp-on message from the CAB, it will light the lamp for the duration of the ABS malfunction. The CAB will also flash this lamp during the diagnostic mode, unless a hard fault is present. If a hard fault is present, the ABS lamp will illuminate without flashing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > General Information > Page 4272 ABS Light: Description and Operation Rear Wheel Antilock Brakes The amber ABS warning lamp is used to alert the driver of an RWAL problem and identify Diagnostic Trouble Codes (DTCs) stored in the Controller Antilock Brake (CAB's) memory. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > General Information > Page 4273 ABS Light: Description and Operation Four Wheel Antilock Brakes The amber ABS warning lamp is located in the instrument cluster. The lamp illuminates at start-up to perform a self check. The lamp goes out when the self check program determines the system is operating normal. If an ABS component exhibits a fault the Controller Antilock Brake (CAB) will illuminate the lamp and register a trouble code in the microprocessor. The lamp is controlled by the CAB. The CAB controls the lamp sending a message to the instrument cluster. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Testing and Inspection > Pinpoint Tests ABS Light: Pinpoint Tests Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Testing and Inspection > Pinpoint Tests > Page 4276 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Testing and Inspection > Pinpoint Tests > Page 4277 ABS Light: Component Tests and General Diagnostics The diagnosis found here addresses an inoperative Anti-lock Brake System (ABS) lamp condition. If the ABS lamp stays on with the ignition switch in the On position, or comes on and stays on while driving. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the ABS lamp fails to light when the ignition switch is turned to the On position, replace the ABS lamp bulb with a known good unit. If the ABS lamp still fails to operate, diagnosis of the ABS system and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool as described in the proper Diagnostic Procedures. For further diagnosis of the ABS lamp and the instrument cluster circuitry, see Instrument Cluster in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Description and Operation Braking Sensor/Switch: Description and Operation An input from this switch prepares the CAB for a possible antilock stop. The antilock system uses an input signal from the brake pedal activated switch. When the driver applies the brake pedal, the circuit voltage is 12 volts. A released brake pedal will close the switch circuit and provide O volts. This signal tells the CAB that the pedal is depressed Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Diagnostic Connector - ABS: Locations NOTE: Chrysler does not provide a procedrure to retrieve ABS diagnostic trouble codes without a scan tool Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Page 4284 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion Technical Service Bulletin # D20 Date: 040901 Recall - ABS Wiring Corrosion September 2004 Dealer Service Instructions for: Safety Recall D20 - ABS Wiring Corrosion Models 1998-2003 (AB) Dodge Ram Van/Wagon NOTE: This recall applies only to the above vehicles equipped with a 4-wheel Anti-lock Brake System (ABS) (sales code BGK). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject Electrolyte (battery acid) from aftermarket batteries may leak onto an Antilock Brake System (ABS) wiring connector on about 43,000 of the above vehicles. This may cause the wiring to corrode and short circuit, which can result in an underhood fire. Repair All vehicles must have a revised battery tray installed that will protect the ABS control module wiring harness connector from future electrolyte leakage. A cowl seal extension must also be installed on all vehicles to redirect any water draining from the windshield away from the battery. The ABS control module wiring harness and connector must be inspected for electrolyte damage and repaired if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4293 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4294 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4295 Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Install Cowl Seal Extension 1. Open the hood. 2. Using Mopar glass cleaner and a shop cloth, clean the plastic cowl panel where the cowl seal ends on the driver's side of the vehicle (Figure 1). 3. Test fit the cowl seal extension. Cut the cowl seal extension length so that the seal stops at the end of the plastic cowl panel (Figure 1). 4. Insert the cowl seal connector halfway into the cowl seal extension (Figure 2). 5. Remove the protective plastic covering from the glue strip on the cowl seal extension. 6. Install the cowl seal extension connector into the original cowl seal end and firmly press the seal against the plastic cowl panel (Figure 2). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4296 7. Continue with Section B. Inspect ABS Control Module Wiring Harness Connector. B. Inspect ABS Control Module Wiring Harness Connector 1. Turn the ignition switch to the "Off" position. Be certain that all electrical accessories are turned off. 2. Loosen the battery negative cable clamp pinch-bolt hex nut. 3. Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 4. Loosen the battery positive cable terminal clamp pinch-bolt hex nut. 5. Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 6. Remove the two nuts with washers that secure the battery hold down strap to the threaded end of the J-bolt and the long stud (Figure 4). 7. Remove the battery hold down strap from the top of the battery (Figure 4). 8. Remove the J-bolt from the holes in the battery tray support on the inboard side of the battery tray (Figure 4). 9. Carefully remove the battery from the battery tray. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4297 WARNING: Wear a suitable pair of rubber gloves when removing the battery. Safety glasses should also be worn. 10. Remove the three screws that secure the bottom of the battery tray to the battery tray support (Figure 5). 11. Remove the two screws that secure the outboard side of the battery tray to the left cowl side panel (Figure 5). 12. Lift the battery tray slightly and disconnect the battery temperature sensor electrical connector. 13. Remove the battery tray and the drain tube from the vehicle as an assembly (Figure 5). 14. In the area below the battery location, inspect the front (large) wiring harness connector on the ABS control module for acid damage, by spraying the connector and surrounding area with the provided Electrolyte Detection and Neutralizing Spray (Figure 6). > If the spray remains an orange color, there is no electrolyte (battery acid) on the ABS control module wiring harness connector. Continue with Section E - Battery Tray Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4298 > If the spray turns a purple color, continue with Step 15 of this procedure. 15. Disconnect the large ABS control module wiring harness connector from the ABS control module by first sliding the red lock tab forward. Then push down on the black release tab while pulling the connector from the module (Figure 7). 16. Inspect the large ABS control module wiring harness connector: a. If a heat damaged (melted) connector is found, replace the wiring harness connector. Continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no heat damage is found continue with inspection Step b. b. Inspect the wire side and the terminal side of the large ABS control module wiring harness connector for green colored corrosion. If green colored corrosion is found in one or more of the connector cavities continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no green colored corrosion is found, continue with inspection Step c. c. Looking into the terminal side of the large ABS control module wiring harness connector, inspect the metal terminals for a dull finish or discoloration. If a dull finish or discoloration is found, continue with Section C - ABS Control Module Wiring Harness Connector Replacement because the original connector housing wire weather seals have been damaged. If no dull or discolored terminals are found continue with Section E - Battery Tray Installation. C. ABS Control Module Wiring Harness Connector Replacement NOTE: Only ABS control module wiring harness connectors with heat damage (melted), green wire terminals or dull/discolored terminals, as determined by the inspection in Section B, require replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4299 1. Remove the secondary terminal lock from the original ABS control module wiring harness connector housing (Figure 8). 2. Some models may have two empty wire cavities in the ABS control module wiring harness connector housing. Insert the gray wire cavity plugs supplied with the repair kit into the correct cavities of the new ABS control module wiring harness connector. 3. The ABS control module wiring harness connector terminals that do not have heat damage, green corrosion or are only dull or discolored can be transferred to the new connector using the following process: a. From the terminal side of the connector, insert a small pick into the connector next to the terminal and push on the terminal release arm while pulling on the wire. CAUTION: Remove only one wire from the original connector at a time and note which connector cavity the wire is to be transfer into. b. Using the electrolyte detection and neutralizing spray, lightly spray the removed wire until the spray remains an orange color. This may require two or three applications. c. Using compressed air, carefully dry the terminal and wire. d. Insert the terminal into the proper connector cavity of the new connector housing. e. Repeat Steps a. through d. on all wires that need to be transferred to the new connector housing. 4. The ABS control module wiring harness connector terminals with heat damage and/or green corrosion must be replaced using the following process: a. Cut off the wire one inch back from the original ABS connector. b. Remove one-half (1/2) inch (13 mm) of insulation from the wire on the harness that needs to be spliced. c. Cut the replacement wire supplied in the connector repair kit to the required length. Then remove one-half (1/2) inch (13 mm) of insulation from the wire. d. Place a piece of sealant lined heat shrink tubing on one side of the wire. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4300 e. Place the strands of wire overlapping each other inside of the brass splice band (Figure 9). f. Using crimp tool (Mopar P/N 05019912AA), crimp the brass splice band and wires together (Figure 10). g. Solder the connection together using rosin core type solder. DO NOT use acid core solder. CAUTION: All splices must be properly soldered. Failure to properly solder these wiring connectors can cause the ABS to become inoperative in the future. h. Center the shrink tubing over the splice joint. Using a heat gun, heat the surface of the shrink tubing until the shrink tubing is tightly sealed and sealant comes out of both ends of the shrink tubing (Figure 11). 5. After all of the terminals have been transferred or replaced, install the blue secondary terminal lock into the ABS control module wiring harness connector (Figure 8). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4301 6. Using a small mirror (Snap-on GA295 or equivalent), inspect the ABS control module connector pins for green corrosion and the connector housing for heat damage (Figure 12). > ABS control module connectors found with green corroded pins continue with Section D - ABS Control Module Replacement. > ABS control module connector housings found with heat damage continue with Section D - ABS Control Module Replacement. > ABS control module connectors found without heat damage or green corroded pins continue with Section E - Battery Tray Installation. D. ABS Control Module Replacement NOTE: Only ABS control modules with a heat damaged (melted) connector or green corroded connector pins, as determined by the inspection in Section B and C, require replacement. Very few vehicles are expected to require ABS control module replacement. 1. Disconnect the small ABS control module wiring connector from the ABS control module (Figure 13). 2. Remove the four mounting screws on the ABS control module (Figure 13). 3. Lift the module from the ABS hydraulic control unit and disconnect the solenoid connector located on the bottom side of the ABS control module. 4. Remove the ABS control module from the vehicle and discard. 5. Using a clean shop towel, clean the ABS control module mounting surface on the ABS hydraulic control unit. 6. Connect the solenoid connector to the new ABS control module and then place the module into position on the ABS hydraulic control unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4302 7. Install the four ABS control module mounting screws. Tighten the screws to 39 in. lbs (4.4 N.m). 8. Continue with Section E - Battery Tray Installation. E. Battery Tray Installation 1. If disconnected, spray the ABS control module connector and the ABS control module wiring harness connector with Electrolyte Detection and Neutralizing spray to ensure that all traces of acid have been neutralized. NOTE: When the spray remains an orange color, any remaining battery acid has been neutralized. 2. Using compressed air, carefully blow out the connector until completely dry. 3. If previously disconnected, connect the large and/or small wiring harness connectors to the ABS control module. 4. Transfer the battery temperature sensor from the old battery tray to the new battery tray (Figure 14). Then discard the old battery tray. 5. Place a small bead of RTV silicone rubber adhesive (P/N 04883971) onto the base of the new drain tube grommet. 6. Snap the new drain tube into position on the new battery tray (Figure 14). 7. While installing the new battery tray into position, route the drain tube through the original hole in the fender panel (Figure 15) and connect the battery temperature sensor electrical connector. 8. Install the battery tray mounting bolts. Tighten the bolts to 95 in. lbs. (10.7 N.m). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4303 9. Install the battery onto the new battery tray. 10. Install the "J" hook and battery hold down bracket. 11. Install the battery hold down retaining nuts. Tighten the nuts to 24 in. lbs. (2.7 N.m). 12. Connect the positive battery cable to the positive battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 13. Connect the negative battery cable to the negative battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 14. From inside the left wheel well housing, secure the battery tray drain tube to the frame rail bracket with the provided plastic tie strap (Figure 16). 15. If the ABS control module was replaced, connect the DRB III scan tool to the vehicle and program the rear axle ratio and tire size into the new control module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4304 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA04V185000 > Apr > 04 > Recall 04V185000: ABS Control Module Corrosion Electronic Brake Control Module: Recalls Recall 04V185000: ABS Control Module Corrosion DEFECT: On some van and wagon model vehicles equipped with 4-wheel antilock brake systems (ABS), aftermarket batteries may leak electrolyte onto the ABS control module connector, which can compromise the sealing integrity of the connector. This may allow development of a short circuit in the connector, which could eventually lead to a fire. REMEDY: Dealers will inspect the ABS control module connector for electrolyte damage and replace the connector as necessary. The manufacturer has not yet provided an owner notification for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-002-02 > Jan > 02 > Rear Axle - Vehicle Speed Is Inaccurate Electronic Brake Control Module: Customer Interest Rear Axle - Vehicle Speed Is Inaccurate NUMBER: 18-002-02 GROUP: Vehicle Performance DATE: January 21, 2002 THE MDS2(R) MUST BE OPERATING WITH CIS CD2094 OR HIGHER, AVAILABLE OCTOBER 29, 2001. THE DRBIII(R) MUST BE AT LEVEL 52.5 OR LATER. SUBJECT: Pinion Factor Recalibration MODELS: 1998-2002 AB Ram Van NOTE: THIS BULLETIN APPLIES TO ALL 1998 - 2002 (AB) RAM VANS EQUIPPED WITH THE 9.25 REAR AXLE. DISCUSSION: Owners of 1998 - 2002 (AB) Ram Vans equipped with the 9.25 rear axle may complain that vehicle speed is inaccurate. It may be that past service on the rear axle has caused the calibration to change. Accurate calibration can be restored by reprogramming the applicable module, (ABS) Antilock Brake System or (RWAL) Rear Wheel Antilock, using the DRBI III(R). NOTE: THE DRBIII(R) MUST BE AT LEVEL 52.5 OR HIGHER AND THE MDSII(R) AT CD 2094 OR HIGHER TO PERFORM THE REPROGRAMMING. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion Technical Service Bulletin # D20 Date: 040901 Recall - ABS Wiring Corrosion September 2004 Dealer Service Instructions for: Safety Recall D20 - ABS Wiring Corrosion Models 1998-2003 (AB) Dodge Ram Van/Wagon NOTE: This recall applies only to the above vehicles equipped with a 4-wheel Anti-lock Brake System (ABS) (sales code BGK). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject Electrolyte (battery acid) from aftermarket batteries may leak onto an Antilock Brake System (ABS) wiring connector on about 43,000 of the above vehicles. This may cause the wiring to corrode and short circuit, which can result in an underhood fire. Repair All vehicles must have a revised battery tray installed that will protect the ABS control module wiring harness connector from future electrolyte leakage. A cowl seal extension must also be installed on all vehicles to redirect any water draining from the windshield away from the battery. The ABS control module wiring harness and connector must be inspected for electrolyte damage and repaired if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4319 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4320 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4321 Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Install Cowl Seal Extension 1. Open the hood. 2. Using Mopar glass cleaner and a shop cloth, clean the plastic cowl panel where the cowl seal ends on the driver's side of the vehicle (Figure 1). 3. Test fit the cowl seal extension. Cut the cowl seal extension length so that the seal stops at the end of the plastic cowl panel (Figure 1). 4. Insert the cowl seal connector halfway into the cowl seal extension (Figure 2). 5. Remove the protective plastic covering from the glue strip on the cowl seal extension. 6. Install the cowl seal extension connector into the original cowl seal end and firmly press the seal against the plastic cowl panel (Figure 2). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4322 7. Continue with Section B. Inspect ABS Control Module Wiring Harness Connector. B. Inspect ABS Control Module Wiring Harness Connector 1. Turn the ignition switch to the "Off" position. Be certain that all electrical accessories are turned off. 2. Loosen the battery negative cable clamp pinch-bolt hex nut. 3. Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 4. Loosen the battery positive cable terminal clamp pinch-bolt hex nut. 5. Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 6. Remove the two nuts with washers that secure the battery hold down strap to the threaded end of the J-bolt and the long stud (Figure 4). 7. Remove the battery hold down strap from the top of the battery (Figure 4). 8. Remove the J-bolt from the holes in the battery tray support on the inboard side of the battery tray (Figure 4). 9. Carefully remove the battery from the battery tray. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4323 WARNING: Wear a suitable pair of rubber gloves when removing the battery. Safety glasses should also be worn. 10. Remove the three screws that secure the bottom of the battery tray to the battery tray support (Figure 5). 11. Remove the two screws that secure the outboard side of the battery tray to the left cowl side panel (Figure 5). 12. Lift the battery tray slightly and disconnect the battery temperature sensor electrical connector. 13. Remove the battery tray and the drain tube from the vehicle as an assembly (Figure 5). 14. In the area below the battery location, inspect the front (large) wiring harness connector on the ABS control module for acid damage, by spraying the connector and surrounding area with the provided Electrolyte Detection and Neutralizing Spray (Figure 6). > If the spray remains an orange color, there is no electrolyte (battery acid) on the ABS control module wiring harness connector. Continue with Section E - Battery Tray Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4324 > If the spray turns a purple color, continue with Step 15 of this procedure. 15. Disconnect the large ABS control module wiring harness connector from the ABS control module by first sliding the red lock tab forward. Then push down on the black release tab while pulling the connector from the module (Figure 7). 16. Inspect the large ABS control module wiring harness connector: a. If a heat damaged (melted) connector is found, replace the wiring harness connector. Continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no heat damage is found continue with inspection Step b. b. Inspect the wire side and the terminal side of the large ABS control module wiring harness connector for green colored corrosion. If green colored corrosion is found in one or more of the connector cavities continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no green colored corrosion is found, continue with inspection Step c. c. Looking into the terminal side of the large ABS control module wiring harness connector, inspect the metal terminals for a dull finish or discoloration. If a dull finish or discoloration is found, continue with Section C - ABS Control Module Wiring Harness Connector Replacement because the original connector housing wire weather seals have been damaged. If no dull or discolored terminals are found continue with Section E - Battery Tray Installation. C. ABS Control Module Wiring Harness Connector Replacement NOTE: Only ABS control module wiring harness connectors with heat damage (melted), green wire terminals or dull/discolored terminals, as determined by the inspection in Section B, require replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4325 1. Remove the secondary terminal lock from the original ABS control module wiring harness connector housing (Figure 8). 2. Some models may have two empty wire cavities in the ABS control module wiring harness connector housing. Insert the gray wire cavity plugs supplied with the repair kit into the correct cavities of the new ABS control module wiring harness connector. 3. The ABS control module wiring harness connector terminals that do not have heat damage, green corrosion or are only dull or discolored can be transferred to the new connector using the following process: a. From the terminal side of the connector, insert a small pick into the connector next to the terminal and push on the terminal release arm while pulling on the wire. CAUTION: Remove only one wire from the original connector at a time and note which connector cavity the wire is to be transfer into. b. Using the electrolyte detection and neutralizing spray, lightly spray the removed wire until the spray remains an orange color. This may require two or three applications. c. Using compressed air, carefully dry the terminal and wire. d. Insert the terminal into the proper connector cavity of the new connector housing. e. Repeat Steps a. through d. on all wires that need to be transferred to the new connector housing. 4. The ABS control module wiring harness connector terminals with heat damage and/or green corrosion must be replaced using the following process: a. Cut off the wire one inch back from the original ABS connector. b. Remove one-half (1/2) inch (13 mm) of insulation from the wire on the harness that needs to be spliced. c. Cut the replacement wire supplied in the connector repair kit to the required length. Then remove one-half (1/2) inch (13 mm) of insulation from the wire. d. Place a piece of sealant lined heat shrink tubing on one side of the wire. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4326 e. Place the strands of wire overlapping each other inside of the brass splice band (Figure 9). f. Using crimp tool (Mopar P/N 05019912AA), crimp the brass splice band and wires together (Figure 10). g. Solder the connection together using rosin core type solder. DO NOT use acid core solder. CAUTION: All splices must be properly soldered. Failure to properly solder these wiring connectors can cause the ABS to become inoperative in the future. h. Center the shrink tubing over the splice joint. Using a heat gun, heat the surface of the shrink tubing until the shrink tubing is tightly sealed and sealant comes out of both ends of the shrink tubing (Figure 11). 5. After all of the terminals have been transferred or replaced, install the blue secondary terminal lock into the ABS control module wiring harness connector (Figure 8). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4327 6. Using a small mirror (Snap-on GA295 or equivalent), inspect the ABS control module connector pins for green corrosion and the connector housing for heat damage (Figure 12). > ABS control module connectors found with green corroded pins continue with Section D - ABS Control Module Replacement. > ABS control module connector housings found with heat damage continue with Section D - ABS Control Module Replacement. > ABS control module connectors found without heat damage or green corroded pins continue with Section E - Battery Tray Installation. D. ABS Control Module Replacement NOTE: Only ABS control modules with a heat damaged (melted) connector or green corroded connector pins, as determined by the inspection in Section B and C, require replacement. Very few vehicles are expected to require ABS control module replacement. 1. Disconnect the small ABS control module wiring connector from the ABS control module (Figure 13). 2. Remove the four mounting screws on the ABS control module (Figure 13). 3. Lift the module from the ABS hydraulic control unit and disconnect the solenoid connector located on the bottom side of the ABS control module. 4. Remove the ABS control module from the vehicle and discard. 5. Using a clean shop towel, clean the ABS control module mounting surface on the ABS hydraulic control unit. 6. Connect the solenoid connector to the new ABS control module and then place the module into position on the ABS hydraulic control unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4328 7. Install the four ABS control module mounting screws. Tighten the screws to 39 in. lbs (4.4 N.m). 8. Continue with Section E - Battery Tray Installation. E. Battery Tray Installation 1. If disconnected, spray the ABS control module connector and the ABS control module wiring harness connector with Electrolyte Detection and Neutralizing spray to ensure that all traces of acid have been neutralized. NOTE: When the spray remains an orange color, any remaining battery acid has been neutralized. 2. Using compressed air, carefully blow out the connector until completely dry. 3. If previously disconnected, connect the large and/or small wiring harness connectors to the ABS control module. 4. Transfer the battery temperature sensor from the old battery tray to the new battery tray (Figure 14). Then discard the old battery tray. 5. Place a small bead of RTV silicone rubber adhesive (P/N 04883971) onto the base of the new drain tube grommet. 6. Snap the new drain tube into position on the new battery tray (Figure 14). 7. While installing the new battery tray into position, route the drain tube through the original hole in the fender panel (Figure 15) and connect the battery temperature sensor electrical connector. 8. Install the battery tray mounting bolts. Tighten the bolts to 95 in. lbs. (10.7 N.m). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4329 9. Install the battery onto the new battery tray. 10. Install the "J" hook and battery hold down bracket. 11. Install the battery hold down retaining nuts. Tighten the nuts to 24 in. lbs. (2.7 N.m). 12. Connect the positive battery cable to the positive battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 13. Connect the negative battery cable to the negative battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 14. From inside the left wheel well housing, secure the battery tray drain tube to the frame rail bracket with the provided plastic tie strap (Figure 16). 15. If the ABS control module was replaced, connect the DRB III scan tool to the vehicle and program the rear axle ratio and tire size into the new control module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4330 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > NHTSA04V185000 > Apr > 04 > Recall 04V185000: ABS Control Module Corrosion Electronic Brake Control Module: All Technical Service Bulletins Recall 04V185000: ABS Control Module Corrosion DEFECT: On some van and wagon model vehicles equipped with 4-wheel antilock brake systems (ABS), aftermarket batteries may leak electrolyte onto the ABS control module connector, which can compromise the sealing integrity of the connector. This may allow development of a short circuit in the connector, which could eventually lead to a fire. REMEDY: Dealers will inspect the ABS control module connector for electrolyte damage and replace the connector as necessary. The manufacturer has not yet provided an owner notification for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 18-002-02 > Jan > 02 > Rear Axle - Vehicle Speed Is Inaccurate Electronic Brake Control Module: All Technical Service Bulletins Rear Axle - Vehicle Speed Is Inaccurate NUMBER: 18-002-02 GROUP: Vehicle Performance DATE: January 21, 2002 THE MDS2(R) MUST BE OPERATING WITH CIS CD2094 OR HIGHER, AVAILABLE OCTOBER 29, 2001. THE DRBIII(R) MUST BE AT LEVEL 52.5 OR LATER. SUBJECT: Pinion Factor Recalibration MODELS: 1998-2002 AB Ram Van NOTE: THIS BULLETIN APPLIES TO ALL 1998 - 2002 (AB) RAM VANS EQUIPPED WITH THE 9.25 REAR AXLE. DISCUSSION: Owners of 1998 - 2002 (AB) Ram Vans equipped with the 9.25 rear axle may complain that vehicle speed is inaccurate. It may be that past service on the rear axle has caused the calibration to change. Accurate calibration can be restored by reprogramming the applicable module, (ABS) Antilock Brake System or (RWAL) Rear Wheel Antilock, using the DRBI III(R). NOTE: THE DRBIII(R) MUST BE AT LEVEL 52.5 OR HIGHER AND THE MDSII(R) AT CD 2094 OR HIGHER TO PERFORM THE REPROGRAMMING. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 18-002-02 > Jan > 02 > Rear Axle - Vehicle Speed Is Inaccurate Electronic Brake Control Module: All Technical Service Bulletins Rear Axle - Vehicle Speed Is Inaccurate NUMBER: 18-002-02 GROUP: Vehicle Performance DATE: January 21, 2002 THE MDS2(R) MUST BE OPERATING WITH CIS CD2094 OR HIGHER, AVAILABLE OCTOBER 29, 2001. THE DRBIII(R) MUST BE AT LEVEL 52.5 OR LATER. SUBJECT: Pinion Factor Recalibration MODELS: 1998-2002 AB Ram Van NOTE: THIS BULLETIN APPLIES TO ALL 1998 - 2002 (AB) RAM VANS EQUIPPED WITH THE 9.25 REAR AXLE. DISCUSSION: Owners of 1998 - 2002 (AB) Ram Vans equipped with the 9.25 rear axle may complain that vehicle speed is inaccurate. It may be that past service on the rear axle has caused the calibration to change. Accurate calibration can be restored by reprogramming the applicable module, (ABS) Antilock Brake System or (RWAL) Rear Wheel Antilock, using the DRBI III(R). NOTE: THE DRBIII(R) MUST BE AT LEVEL 52.5 OR HIGHER AND THE MDSII(R) AT CD 2094 OR HIGHER TO PERFORM THE REPROGRAMMING. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion Technical Service Bulletin # D20 Date: 040901 Recall - ABS Wiring Corrosion September 2004 Dealer Service Instructions for: Safety Recall D20 - ABS Wiring Corrosion Models 1998-2003 (AB) Dodge Ram Van/Wagon NOTE: This recall applies only to the above vehicles equipped with a 4-wheel Anti-lock Brake System (ABS) (sales code BGK). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject Electrolyte (battery acid) from aftermarket batteries may leak onto an Antilock Brake System (ABS) wiring connector on about 43,000 of the above vehicles. This may cause the wiring to corrode and short circuit, which can result in an underhood fire. Repair All vehicles must have a revised battery tray installed that will protect the ABS control module wiring harness connector from future electrolyte leakage. A cowl seal extension must also be installed on all vehicles to redirect any water draining from the windshield away from the battery. The ABS control module wiring harness and connector must be inspected for electrolyte damage and repaired if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4349 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4350 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4351 Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Install Cowl Seal Extension 1. Open the hood. 2. Using Mopar glass cleaner and a shop cloth, clean the plastic cowl panel where the cowl seal ends on the driver's side of the vehicle (Figure 1). 3. Test fit the cowl seal extension. Cut the cowl seal extension length so that the seal stops at the end of the plastic cowl panel (Figure 1). 4. Insert the cowl seal connector halfway into the cowl seal extension (Figure 2). 5. Remove the protective plastic covering from the glue strip on the cowl seal extension. 6. Install the cowl seal extension connector into the original cowl seal end and firmly press the seal against the plastic cowl panel (Figure 2). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4352 7. Continue with Section B. Inspect ABS Control Module Wiring Harness Connector. B. Inspect ABS Control Module Wiring Harness Connector 1. Turn the ignition switch to the "Off" position. Be certain that all electrical accessories are turned off. 2. Loosen the battery negative cable clamp pinch-bolt hex nut. 3. Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 4. Loosen the battery positive cable terminal clamp pinch-bolt hex nut. 5. Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 6. Remove the two nuts with washers that secure the battery hold down strap to the threaded end of the J-bolt and the long stud (Figure 4). 7. Remove the battery hold down strap from the top of the battery (Figure 4). 8. Remove the J-bolt from the holes in the battery tray support on the inboard side of the battery tray (Figure 4). 9. Carefully remove the battery from the battery tray. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4353 WARNING: Wear a suitable pair of rubber gloves when removing the battery. Safety glasses should also be worn. 10. Remove the three screws that secure the bottom of the battery tray to the battery tray support (Figure 5). 11. Remove the two screws that secure the outboard side of the battery tray to the left cowl side panel (Figure 5). 12. Lift the battery tray slightly and disconnect the battery temperature sensor electrical connector. 13. Remove the battery tray and the drain tube from the vehicle as an assembly (Figure 5). 14. In the area below the battery location, inspect the front (large) wiring harness connector on the ABS control module for acid damage, by spraying the connector and surrounding area with the provided Electrolyte Detection and Neutralizing Spray (Figure 6). > If the spray remains an orange color, there is no electrolyte (battery acid) on the ABS control module wiring harness connector. Continue with Section E - Battery Tray Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4354 > If the spray turns a purple color, continue with Step 15 of this procedure. 15. Disconnect the large ABS control module wiring harness connector from the ABS control module by first sliding the red lock tab forward. Then push down on the black release tab while pulling the connector from the module (Figure 7). 16. Inspect the large ABS control module wiring harness connector: a. If a heat damaged (melted) connector is found, replace the wiring harness connector. Continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no heat damage is found continue with inspection Step b. b. Inspect the wire side and the terminal side of the large ABS control module wiring harness connector for green colored corrosion. If green colored corrosion is found in one or more of the connector cavities continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no green colored corrosion is found, continue with inspection Step c. c. Looking into the terminal side of the large ABS control module wiring harness connector, inspect the metal terminals for a dull finish or discoloration. If a dull finish or discoloration is found, continue with Section C - ABS Control Module Wiring Harness Connector Replacement because the original connector housing wire weather seals have been damaged. If no dull or discolored terminals are found continue with Section E - Battery Tray Installation. C. ABS Control Module Wiring Harness Connector Replacement NOTE: Only ABS control module wiring harness connectors with heat damage (melted), green wire terminals or dull/discolored terminals, as determined by the inspection in Section B, require replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4355 1. Remove the secondary terminal lock from the original ABS control module wiring harness connector housing (Figure 8). 2. Some models may have two empty wire cavities in the ABS control module wiring harness connector housing. Insert the gray wire cavity plugs supplied with the repair kit into the correct cavities of the new ABS control module wiring harness connector. 3. The ABS control module wiring harness connector terminals that do not have heat damage, green corrosion or are only dull or discolored can be transferred to the new connector using the following process: a. From the terminal side of the connector, insert a small pick into the connector next to the terminal and push on the terminal release arm while pulling on the wire. CAUTION: Remove only one wire from the original connector at a time and note which connector cavity the wire is to be transfer into. b. Using the electrolyte detection and neutralizing spray, lightly spray the removed wire until the spray remains an orange color. This may require two or three applications. c. Using compressed air, carefully dry the terminal and wire. d. Insert the terminal into the proper connector cavity of the new connector housing. e. Repeat Steps a. through d. on all wires that need to be transferred to the new connector housing. 4. The ABS control module wiring harness connector terminals with heat damage and/or green corrosion must be replaced using the following process: a. Cut off the wire one inch back from the original ABS connector. b. Remove one-half (1/2) inch (13 mm) of insulation from the wire on the harness that needs to be spliced. c. Cut the replacement wire supplied in the connector repair kit to the required length. Then remove one-half (1/2) inch (13 mm) of insulation from the wire. d. Place a piece of sealant lined heat shrink tubing on one side of the wire. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4356 e. Place the strands of wire overlapping each other inside of the brass splice band (Figure 9). f. Using crimp tool (Mopar P/N 05019912AA), crimp the brass splice band and wires together (Figure 10). g. Solder the connection together using rosin core type solder. DO NOT use acid core solder. CAUTION: All splices must be properly soldered. Failure to properly solder these wiring connectors can cause the ABS to become inoperative in the future. h. Center the shrink tubing over the splice joint. Using a heat gun, heat the surface of the shrink tubing until the shrink tubing is tightly sealed and sealant comes out of both ends of the shrink tubing (Figure 11). 5. After all of the terminals have been transferred or replaced, install the blue secondary terminal lock into the ABS control module wiring harness connector (Figure 8). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4357 6. Using a small mirror (Snap-on GA295 or equivalent), inspect the ABS control module connector pins for green corrosion and the connector housing for heat damage (Figure 12). > ABS control module connectors found with green corroded pins continue with Section D - ABS Control Module Replacement. > ABS control module connector housings found with heat damage continue with Section D - ABS Control Module Replacement. > ABS control module connectors found without heat damage or green corroded pins continue with Section E - Battery Tray Installation. D. ABS Control Module Replacement NOTE: Only ABS control modules with a heat damaged (melted) connector or green corroded connector pins, as determined by the inspection in Section B and C, require replacement. Very few vehicles are expected to require ABS control module replacement. 1. Disconnect the small ABS control module wiring connector from the ABS control module (Figure 13). 2. Remove the four mounting screws on the ABS control module (Figure 13). 3. Lift the module from the ABS hydraulic control unit and disconnect the solenoid connector located on the bottom side of the ABS control module. 4. Remove the ABS control module from the vehicle and discard. 5. Using a clean shop towel, clean the ABS control module mounting surface on the ABS hydraulic control unit. 6. Connect the solenoid connector to the new ABS control module and then place the module into position on the ABS hydraulic control unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4358 7. Install the four ABS control module mounting screws. Tighten the screws to 39 in. lbs (4.4 N.m). 8. Continue with Section E - Battery Tray Installation. E. Battery Tray Installation 1. If disconnected, spray the ABS control module connector and the ABS control module wiring harness connector with Electrolyte Detection and Neutralizing spray to ensure that all traces of acid have been neutralized. NOTE: When the spray remains an orange color, any remaining battery acid has been neutralized. 2. Using compressed air, carefully blow out the connector until completely dry. 3. If previously disconnected, connect the large and/or small wiring harness connectors to the ABS control module. 4. Transfer the battery temperature sensor from the old battery tray to the new battery tray (Figure 14). Then discard the old battery tray. 5. Place a small bead of RTV silicone rubber adhesive (P/N 04883971) onto the base of the new drain tube grommet. 6. Snap the new drain tube into position on the new battery tray (Figure 14). 7. While installing the new battery tray into position, route the drain tube through the original hole in the fender panel (Figure 15) and connect the battery temperature sensor electrical connector. 8. Install the battery tray mounting bolts. Tighten the bolts to 95 in. lbs. (10.7 N.m). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4359 9. Install the battery onto the new battery tray. 10. Install the "J" hook and battery hold down bracket. 11. Install the battery hold down retaining nuts. Tighten the nuts to 24 in. lbs. (2.7 N.m). 12. Connect the positive battery cable to the positive battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 13. Connect the negative battery cable to the negative battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 14. From inside the left wheel well housing, secure the battery tray drain tube to the frame rail bracket with the provided plastic tie strap (Figure 16). 15. If the ABS control module was replaced, connect the DRB III scan tool to the vehicle and program the rear axle ratio and tire size into the new control module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4360 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > NHTSA04V185000 > Apr > 04 > Recall 04V185000: ABS Control Module Corrosion Electronic Brake Control Module: All Technical Service Bulletins Recall 04V185000: ABS Control Module Corrosion DEFECT: On some van and wagon model vehicles equipped with 4-wheel antilock brake systems (ABS), aftermarket batteries may leak electrolyte onto the ABS control module connector, which can compromise the sealing integrity of the connector. This may allow development of a short circuit in the connector, which could eventually lead to a fire. REMEDY: Dealers will inspect the ABS control module connector for electrolyte damage and replace the connector as necessary. The manufacturer has not yet provided an owner notification for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > With RWAL Brakes Electronic Brake Control Module: Specifications With RWAL Brakes Mounting Screws ................................................................................................................................. ....................................................... 4 Nm (36 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > With RWAL Brakes > Page 4367 Electronic Brake Control Module: Specifications With 4-Wheel Antilock Brakes Screws ................................................................................................................................................. ................................................. 4.4 Nm (39 inch lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > EBC 2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > EBC 2 > Page 4370 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock Brake (CAB) Electronic Brake Control Module: Description and Operation Kelsey-Hayes EBC Controller Antilock Brake (CAB) The CAB is mounted under the hood, separately from the valve body, and has a microprocessor and circuits that: - monitor the brake switch input to tell whether or not to prepare for possible antilock braking - monitor the wheel speed sensor inputs to determine when a rear wheel is tending to lock up. - operate the integral control unit assembly during antilock braking based on comparing the speed sensor to information programmed in memory - detect ABS system related problems and take diagnostic action The CAB will disable antilock control and set a hard ignition latched trouble code if it detects one of the following conditions with itself: - (71) RAM Read/Write - (72) ROM Checksum - (73) Watchdog Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock Brake (CAB) > Page 4373 Electronic Brake Control Module: Description and Operation Kelsey-Hayes EBC 325 Controller Antilock Brake (CAB) The CAB is mounted directly to the hydraulic control unit and includes a microprocessor and six solenoids that control brake pressure during antilock braking. The CAB also has circuits that monitor the following: - Brake switch input is monitored to determine whether or not to prepare for possible antilock braking. - Wheel speed sensors are monitored to determine when a wheel is tending to lock up. The CAB will operate the valves in the ECU to control braking pressure during antilock braking. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock Brake (CAB) > Page 4374 Electronic Brake Control Module: Description and Operation With Four Wheel Antilock Brakes CAB/HCU The Controller Antilock Brake (CAB) is mounted on the top of the hydraulic control unit. The CAB operates the ABS system and is separate from other vehicle electrical circuits. CAB voltage source is through the ignition switch in the RUN position. The CAB contains dual microprocessors. A logic block in each microprocessor receives identical sensor signals. These signals are processed and compared simultaneously. The CAB contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the DRB scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock Brake (CAB) > Page 4375 Electronic Brake Control Module: Description and Operation With Rear Wheel Antilock Brakes GENERAL INFORMATION RWAL Controller Antilock Brake (CAB) The Controller Antilock Brakes (CAB) is a microprocessor which handles testing, monitoring and controlling the ABS brake system operation. The CAB functions are: Perform self-test diagnostics. - Monitors the RWAL brake system for proper operation. - Controls the RWAL valve solenoids. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. SYSTEM SELF-TEST When the ignition switch is turned-on the microprocessor RAM and ROM are tested. If an error occurs during the test a Diagnostic Trouble Code (DTC) will be set into the RAM memory. However it is possible the DTC will not be stored in memory if the error has occurred in the RAM module were the DTC's are stored. Also it is possible a DTC may not be stored if the error has occurred in the ROM which signals the RAM to store the DTC. CAB INPUTS The CAB continuously monitors the speed of the differential ring gear by monitoring signals generated by the rear wheel speed sensor. The CAB determines a wheel locking tendency when it recognizes the ring gear decelerating too rapidly. The CAB monitors the following inputs to determine when a wheel locking tendency may exists: - Rear Wheel Speed Sensor - Brake Lamp Switch - Brake Warning Lamp Switch - Reset Switch - 4WD Switch (If equipped) CAB OUTPUTS The CAB controls the following outputs for antilock braking and brake warning information: RWAL Valve - ABS Warning Lamp - Brake Warning Lamp Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System Electronic Brake Control Module: Service and Repair Four Wheel Antilock Brake System NOTE: If the Controller Antilock Brake (CAB) needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. REMOVAL 1. Disconnect battery cables and remove the battery. 2. Remove the power distribution center. 3. Remove the battery and power distribution center mount. 4. Remove the washer reservoir mounting screws. 5. Lift up the reservoir and disconnect the pump motor connector and pump hose. 6. Remove the reservoir from the engine compartment. Harness Connector Locks 7. Push the harness connector locks to release the locks, then remove the connectors from the CAB. Pump Motor Connector 8. Disconnect the pump motor connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 4378 Controller Mounting Screws 9. Remove screws attaching CAB to the Hydraulic Control Unit (HCU). 10. Remove the CAB. INSTALLATION 1. Place the CAB onto the HCU. NOTE: Insure the CAB seal is in position before installation. 2. Install the mounting screws and tighten to 4.4 Nm (39 inch lbs.). 3. Connect the pump motor harness. 4. Connect the harnesses to the CAB and lock the connectors. 5. Install the reservoir in the engine compartment. Connect the pump motor connector and pump hose. 6. Install the washer reservoir mounting screws. 7. Install the battery and power distribution center mount. 8. Install the power distribution center. 9. Install the battery and battery cables. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 4379 Electronic Brake Control Module: Service and Repair Rear Wheel Antilock Brake System NOTE: If the Controller Antilock Brake (CAB) needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. REMOVAL 1. Remove the washer reservoir mounting screws. 2. Lift up the reservoir and disconnect the pump motor connector and pump hose. 3. Remove the reservoir from the engine compartment. 4. Disconnect battery cables and remove the battery. 5. Remove the power distribution center. 6. Remove the battery and power distribution center mount. 7. Remove the RWAL valve harness. 8. Pull up on the CAB harness connector lock release and remove the connector from the controller. 9. Remove controller mounting screws and remove controller. INSTALLATION 1. Position the controller on the mounting bracket and install the mounting screws. 2. Install the CAB harness connector into the controller and push down on the connector lock. 3. Install the RWAL valve harness connector into controller. 4. Install the battery and power distribution center mount. 5. Install the power distribution center. 6. Install the battery and battery cables. 7. Install the reservoir in the engine compartment. Connect the pump motor connector and pump hose. 8. Install the washer reservoir mounting screws. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > With Four Wheel Antilock Brakes Hydraulic Control Assembly - Antilock Brakes: Specifications With Four Wheel Antilock Brakes Bracket Nuts ........................................................................................................................................ ................................................ 12 Nm (102 inch lbs.) Mounting Bolts ................................................. ........................................................................................................................................ 15 Nm (11 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > With Four Wheel Antilock Brakes > Page 4384 Hydraulic Control Assembly - Antilock Brakes: Specifications With Rear Wheel Antilock Brakes Bracket Nuts ........................................................................................................................................ ................................................ 12 Nm (102 inch lbs.) Valve Bolt ........................................................ ......................................................................................................................................... 24 Nm (18 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > General Information Hydraulic Control Assembly - Antilock Brakes: Description and Operation General Information The controller-antilock brake module is used to monitor wheel speeds and modulates (control) hydraulic pressure in each brake channel. The modulated hydraulic pressure is used to prevent wheel lock up during braking. The CAB also provides a vehicle speed signal (VSS) to the powertrain control module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > General Information > Page 4387 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control Unit (HCU) Description The HCU on the EBC 2 has only a separate rear valve body. The HCU on the EBC 325 has two integral valve bodies for controlling the front and rear brakes. Within the HCU are solenoids, valves, check valves, and a reset switch necessary to apply and release brake pressure as required to avoid wheel lockup, keep the wheels rolling, and maintain optimum deceleration. The isolation valve is normally open, allowing unrestricted flow from the master cylinder to the wheels. When the CAB determines antilock intervention is required, the valve closes to isolate the master cylinder hydraulic circuit. Fluid is trapped in the circuit and then prevented from reaching the wheels. The dump valve is pulsed on and off by the CAB. This valve cycles only if the isolation valve is closed. When dump is on, it allows fluid to the low pressure accumulator for temporary storage. This causes the pressure to the wheel to decrease. When the valve is off, fluid is allowed to the wheel. The brake return check valve allows the HCU to drain faster after the ABS stop, when the brake is released. The Reset Switch is positioned in the HCU to monitor the master cylinder (input), rear brake (output) and accumulator pressure. During normal braking, pressure is equal for input and output and the switch remains open. During an Antilock stop the switch will close as the isolation valve is cycled and pressure becomes unequal between input and output. At the end of an ABS stop the isolation valve will open as master cylinder pressure and rear pressure equalize. The switch is used to monitor correct operation of the HCU and to set a diagnostic trouble code if incorrect pressure is detected. When the brakes are applied, fluid is forced from the master cylinder outlet ports to the HCU inlet ports. This pressure is transmitted through three normally open isolation valves inside the HCU, then through the outlet ports of the HCU to the wheels. If the CAB senses that a wheel is about to lock, based on wheel speed sensor data, it pulls the normally open isolation valve closed for that circuit. This prevents any more fluid from entering that circuit. The CAB continues to look at the sensor signal to determine if the wheel is still decelerating. If deceleration is still taking place, the normally closed dump valve for that circuit is opened. This dumps any pressure that is trapped between the normally open valve and the brake back into an accumulator. Once the affected circuit comes back up to speed, the CAB returns the valves to their normal condition allowing the affected brake to be reapplied. On the EBC 325 system, the pump and accumulators are used to provide rapid response during the reapply sequence and to minimize pedal feedback. With Four Wheel Antilock Brakes GENERAL INFORMATION CAB/HCU The Hydraulic Control Unit (HCU) consists of a valve body, pump, accumulator and motor. The pump, motor, and accumulator are combined into an assembly attached to the valve body. The accumulator store the extra fluid which had to be dumped from the brakes. This is done to prevent the wheels from locking up. The pump provides the fluid volume needed and is operated by a DC type motor. The motor is controlled by the Controller Antilock Brake (CAB). The valve body contains the solenoid valves. The valves modulate brake pressure during antilock braking and are controlled by the CAB. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > General Information > Page 4388 The HCU provides three channel pressure control to the front and rear brakes. One channel controls the rear wheel brakes in tandem. The two remaining channels control the front wheel brakes individually. During antilock braking, the solenoid valves are opened and closed as needed. The valves are not static. They are cycled rapidly and continuously to modulate pressure and control wheel slip and deceleration. During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder and power booster operate the same as a vehicle without an ABS brake system. During antilock braking, solenoid valve pressure modulation occurs in three stages, pressure decrease, pressure hold, and pressure increase. The valves are all contained in the valve body portion of the HCU. Pressure Decrease The inlet valve is closed and the outlet valve is opened during the pressure decrease cycle. A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the CAB closes the inlet to prevent the driver from further increasing the brake pressure and locking the brakes. The CAB then opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent wheel lock. Once the period of high wheel slip has ended, the CAB closes the outlet valve and begins a pressure increase or hold cycle as needed. Pressure Hold Both solenoid valves are closed in the pressure hold cycle. Fluid apply pressure in the control channel is maintained at a constant rate. The CAB maintains the hold cycle until sensor inputs indicate a pressure change is necessary. Pressure Increase The inlet valve is open and the outlet valve is closed during the pressure increase cycle. The pressure increase cycle is used to counteract unequal wheel speeds. This cycle controls re-application of fluid apply pressure due to changing road surfaces or wheel speed. With Rear Wheel Antilock Brakes If the Controller Antilock Brake (CAB) senses that rear wheel speed deceleration is excessive, it will energize a isolation solenoid by providing battery voltage to the solenoid. This prevents a further increase of driver induced brake pressure to the rear wheels. If this initial action is not enough to prevent rear wheel lock-up, the CAB will momentarily energize a dump solenoid (the CAB energizes the dump solenoid by providing battery voltage to the solenoid). This opens the dump valve to vent a small amount of isolated rear brake pressure to an accumulator. The action of fluid moving to the accumulator reduces the isolated brake pressure at the wheel cylinders. The dump (pressure venting) cycle is limited to very short time periods (milliseconds). The CAB will pulse the dump valve until rear wheel deceleration matches the vehicle deceleration rate or the desired slip rate programmed into the CAB. The system will switch to normal braking once wheel locking tendencies are no longer present. A predetermined maximum number of consecutive dump cycles can be performed during any one antilock stop. If excessive dump cycles occur, a DTC will be set and stored in the CAB memory. If during an antilock stop, the driver releases the brake pedal, the reset switch contacts will open. This signal to the CAB is an indication that pressure has equalized across the RWAL valve. The CAB will then reset the dump cycle counter in anticipation of the next antilock stop. Additionally, any fluid stored in the accumulator will force its way past the dump valve, back into the hydraulic circuit and return to the master cylinder. A fuse internal to the CAB, provides a fail-safe device which prevents unwanted control over the isolation and dump solenoids. The fuse is in series with the isolation and dump solenoids output circuits. If the internal fuse is open, the CAB cannot provide voltage to energize either solenoid and antilock stops are prevented. If the fuse is open, the braking system will operate normally but without antilock control over rear brake pressure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Front Antilock Valve Replacement NOTE: If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new Controller Antilock Brake (CAB). REMOVAL 1. Remove left turn signal housing. 2. Remove the extension panel under the left turn signal housing opening. Access Cover 3. Disconnect the horn connector and remove the access cover. 4. Remove the washer reservoir mounting screws. 5. Lift up the reservoir and disconnect the pump motor connector and pump hose. 6. Remove the reservoir from the engine compartment. 7. Disconnect battery cables and remove the battery. 8. Remove the power distribution center. 9. Remove the battery and power distribution center mount. Harness Connector Locks 10. Push the harness connectors locks to release the locks, then remove the connectors from the CAB. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement > Page 4391 HCU Brake Lines 11. Disconnect brake lines from Hydraulic Control Unit (HCU). 12. Remove the front mounting bolt through access opening. 13. Remove the rear mounting bolt from the engine compartment. 14. Tilt the assembly upward were the brake lines attach and remove the assembly from the mounting bracket. INSTALLATION 1. Install the assembly into the mounting bracket. 2. Install mounting bolts and tighten to 15 Nm (11 ft. lbs.). 3. Install the brake lines to HCU and tighten to 13 Nm (115 inch lbs.). 4. Connect the CAB harness connectors and lock in place. 5. Install the reservoir in the engine compartment. Connect the pump motor connector and pump hose. 6. Install the washer reservoir mounting screws. 7. Install the battery and power distribution center mount. 8. Install the power distribution center. 9. Install the battery and battery cables. 10. Connect the horn connector and install the access cover. 11. Install the extension panel. 12. Install left turn signal housing. 13. Bleed the brake system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement > Page 4392 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Rear Antilock Valve Replacement REMOVAL 1. Remove left turn signal housing. 2. Remove the extension panel under the left turn signal housing opening. Access Cover 3. Disconnect the horn connector and remove the access cover. 4. Remove one brake line from the rear antilock valve through the access cover opening. 5. From the engine compartment, disconnect antilock valve harness connector from the controller. 6. Remove the other brake line and mounting bolt from the antilock valve. 7. Remove rear antilock valve. INSTALLATION 1. Position rear antilock valve on the valve bracket. 2. Install the mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Install the brake lines and tighten to 15 Nm (130 inch lbs.). 4. Connect wiring harness wires to the controller. 5. Connect the horn connector and install the access cover. 6. Install the extension panel. 7. Install left turn signal housing. 8. Fill and bleed brake system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > With Four Wheel Antilock Brakes Wheel Speed Sensor: Specifications Front Bolt 11 ft.lb Rear Bolt 18 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > With Four Wheel Antilock Brakes > Page 4397 Wheel Speed Sensor: Specifications Mounting Bolt 18 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4400 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4401 Wheel Speed Sensor: Connector Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 4404 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brakes OPERATION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front steering knuckles. The third sensor is mounted on top of the rear axle differential housing. The sensor is a magnet coil that is mounted over a tone wheel front/exciter ring rear with an air gap between them. The sensors measure the wheel speed by monitoring the rotation of the tone wheels front/exciter ring rear. As the teeth of the tone wheels front/exciter ring rear move through the magnetic field of the sensor an AC voltage is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The Controller Antilock Brake (CAB) monitors these signals for changes in wheel deceleration. If the CAB detects a sudden wheel or wheels deceleration within a predetermined amount the CAB will activate the ABS system. CIRCUIT OPERATION The all wheel Anti-Lock Brake System (ABS) uses three wheel speed sensors; a single sensor for both rear wheels and individual sensors for the front wheels. The single sensor used for the rear wheels mounts on the top of the rear axle differential housing. Each sensor converts wheel speed into an electrical signal that is transmitted to the Controller Anti-Lock Brakes (CAB). A pair of twisted wires connect to each sensor and provide signals to the CAB. Circuits B6 and B7 provide signals to the CAB from the right front wheel speed sensor. Circuit B6, which provides the LOW signal, connects to cavity 15 of the CAB. Circuit B7 connects to cavity 2 of the CAB and provides the HIGH signal. Circuits B8 and B9 provide signals to the CAB from the left front wheel speed sensor. Circuit B8, which provides the LOW signal, connects to cavity 16 of the CAB. Circuit B9 connects to cavity 3 and provides the HIGH signal. Circuit B114 connects to cavity 14 of the CAB and to circuit B2 of the rear wheel speed sensor harness at the sensor connector. Circuit B113 connects to cavity 1 of the CAB and to circuit B1 at the rear wheel speed sensor harness connector. Circuit B114 provides the rear wheel speed sensor LOW input while circuit B113 provides the HIGH input. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 4407 Wheel Speed Sensor: Description and Operation Kelsey-Hayes Antilock Brake Systems The EBC 325 ABS system uses one wheel speed sensor on each front wheel, and one speed sensor mounted in the rear axle for the rear wheels. The RWAL II uses only one speed sensor mounted in the rear axle for the rear wheels. The sensor measures the wheel speed by monitoring a rotating tone wheel. The signal generated by the sensor and tone wheel is transmitted to the CAB. Each sensor has: - a metal tone wheel with teeth on its outside diameter - a magnetic/coil pick-up (speed sensor) that is mounted to a fixed component - an air gap between the tone wheel and the speed sensor assembly As the teeth of the tone wheel move through the magnetic field of the sensor, an AC voltage is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The CAB monitors this signal to check for a sudden change in single or multiple wheel decelerations. If the deceleration of one or more wheels is not within a predetermined amount, the antilock module takes control. Diagnostically, the coil of wheel speed sensors have different amounts of resistance based upon the sensor type. When measured across the connector two terminals, the resistance should be: AN, DN, BE and BR: 4x4 front sensors 945-1155 ohms AB, AN and DN: 4x2 front sensors 2500-2955 ohms BE and BR: 4x2 front sensors 1000-1250 ohms AB, AN, DN, BE and BR: All rear sensors 1600-2300 ohms NOTE: For all resistance ranges add 30% to the value for extreme heat, subtract 30% for extreme cold.) The rear wheel speed sensor used on all vehicles have the same resistance value, but there are two different sensors. Therefore, it is important to replace the rear wheel speed sensor with the proper part. On a EBC 325 system each front wheel speed is monitored through the speed sensor mounted at the wheel end of the hub. On a EBC 325 and RWAL II system the rear wheel speed is monitored through the speed sensor mounted in the rear axle assembly. The CAB will disable antilock control, illuminate the ABS warning light circuit via COD, and store trouble codes if it detects a problem with any or all of the wheel speed sensors: - incorrect circuit resistance when checked with no vehicle movement - incorrect sensor output during vehicle movement - erratic sensor output during vehicle movement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 4408 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brakes The rear wheel speed sensor is mounted on the top of the rear axle differential. The sensor converts wheel speed into an electrical signal that is transmitted to the Rear Wheel Anti-Lock (RWAL) control module. Circuits B113 and B114, a pair of twisted wires connect to the sensor and provide signals to the RWAL control module. These circuits also connect to the rolls test connector used only during manufacture of the vehicle. Circuit B113 connects to cavity 14 of the RWAL control module and to circuit B1 of the wheel speed sensor harness. Circuit B114 connects to cavity 13 of the RWAL control module and circuit B2 of the sensor harness. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Front REMOVAL 1. Raise and support vehicle. 2. Disconnect speed sensor from the main harness. Wheel Speed Sensor 3. Remove sensor mounting bolt from the steering knuckle. 4. Remove the sensor from the steering knuckle. INSTALLATION CAUTION: A special bolt is used to attach the sensor. Use only a factory replacement bolt. 1. Install the sensor into the steering knuckle. 2. Install mounting bolt and tighten to 15 Nm (11 ft. lbs.). 3. Connect sensor wire to main harness and ensure wire is routed away from hot or moving components. 4. Remove supports and lower vehicle. With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4411 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 0-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. With Four Wheel Antilock Brakes REMOVAL 1. Raise and support vehicle. Rear Wheel Speed Sensor 2. Disconnect wire from rear sensor on axle housing. 3. Remove sensor and bracket mounting bolt and remove sensor and bracket. INSTALLATION 1. Secure sensor wire to rear brake hose with clips provided. 2. Install sensor and mounting bracket in axle housing. Install mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Connect wire to sensor and secure wire to mounting bracket. 4. Remove support and lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4412 Wheel Speed Sensor: Service and Repair Tone Wheel Replacement Front Tone Wheel Tone Wheel The tone wheel for the front speed sensor is located on the rotor hub. The tone wheel is not a serviceable component. The complete rotor and hub assembly will have to be replaced if the tone wheel is damaged. Rear Tone Wheel The toothed exciter ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, refer to Transmission and Drivetrain for service procedures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures W/ Four Wheel Antilock Brakes ABS system bleeding requires conventional bleeding methods plus use of the DRB scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. W/ Rear Wheel Antilock Brakes GENERAL INFORMATION RWAL brake bleeding can be performed manually, or with pressure bleeding equipment. Use Mopar DOT 3 brake fluid, or an equivalent meeting SAE J1703-F and DOT 3 standards, to fill and bleed the brake system. Bleed only one brake component at a time. Recommended bleed sequence is: master cylinder - combination valve - rear antilock valve - left rear wheel - right rear wheel - right front wheel - left front wheel MANUAL BLEEDING Use a bleed hose at each caliper/cylinder bleed screw. Attach one end of the hose to the bleed screw and insert the opposite end in glass container partially filled with brake fluid. A glass container makes it easier to see air bubbles as they exit the bleed hose. Be sure the end of the bleed hose remains immersed in fluid. This prevents air from being drawn back into the system. Do not allow the master cylinder to run out of fluid when bleeding the brakes. An empty cylinder will allow air to be drawn back into the system. Check fluid level frequently during bleeding operations. Be sure to tighten each brake line fitting, or bleed screw once bleeding is completed. Loose fittings and bleed screws allows air to enter the system. PRESSURE BLEEDING If pressure bleeding equipment will be used, the front brake metering valve will have to be held open to bleed the front brakes. The valve stem is located in the forward end of the combination valve. The stem must either be pressed inward, or held outward slightly. a spring clip tool or helper is needed to hold the valve stem in position. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15 - 20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4417 Brake Bleeding: Service and Repair Base Brake System Bleeding GENERAL INFORMATION Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. Bleed only one brake component at a time in the following sequence: master cylinder - combination valve - right rear wheel - left rear wheel - right front wheel - left front wheel MANUAL BLEEDING 1. Remove reservoir filler caps and fill reservoir with Mopar, or equivalent quality DOT 3 brake fluid. 2. If calipers, or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. Bleed Hose Setup 3. Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. PRESSURE BLEEDING Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15 - 20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Use adapter provided with the equipment or Adapter 6921 or equivalent. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Shaft Nut .............................................................................................................................................. ..................................................... 54 Nm (40 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 4421 Brake Pedal Assy: Description and Operation A suspended-type brake pedal is used for all applications. The pedal is attached to the pedal support bracket with a pivot bolt, sleeve and bushings. The pedal, bolt, sleeve and bushings are all serviceable components. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 4422 Brake Pedal Assy: Service and Repair REMOVAL 1. Remove the knee blocker under the steering column, to access the pedal. Push Rod 2. Remove clip securing push rod to pedal. 3. Remove brake pedal shaft nut. 4. Slide brake pedal shaft out and remove the brake pedal. 5. Remove and inspect pedal bushings. Replace bushings if worn or damaged. INSTALLATION 1. Lubricate pedal shaft and bushings with Mopar multi-mileage grease. 2. Install pedal bushings in pedal, sleeve and support. 3. Position pedal in support and install the pedal shaft. 4. Apply Mopar Lock N' Seal, or 242 Loctite to threads of pedal shaft and shaft retaining nut. 5. Install washer and nut on the pedal shaft. Tighten shaft nut to 54 Nm (40 ft. lbs.). 6. Check and adjust stop lamp switch, if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark 20 ABS System Test Revisions NUMBER: 26-12-97I GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Teves Mark 20 ABS Diagnostic Manual - Publication Number - 81-699-97013 DESCRIPTION OF CHANGES Revisions to the ABS warning lamp test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 4427 94 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 4428 95 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 4429 Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions NUMBER: 26-12-97F GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997-1998 Teves Mark IV, Teves Mark 20 ABS Diagnostic Manual - Publication Number 81-699-97012 DESCRIPTION OF CHANGES Revisions to the ABS warning light procedure Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 4430 244 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 4431 245 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > General Information Brake Warning Indicator: Description and Operation General Information SYSTEM OPERATION The brake warning lamp gives an indication when the parking brake is applied, when the pressures in the two halves of the split brake hydraulic system are unequal, if the Anti-lock Brake System (ABS) lamp has failed and an ABS fault occurs, and during ABS diagnostics. The lamp is turned on by the instrument cluster circuitry for about two seconds when the ignition switch is moved to the Start position as a bulb test. After the bulb test, the lamp is controlled by a hard wired input from the parking brake switch and/or by the instrument cluster circuitry based upon messages received from the Controller Anti-lock Brake (CAB) on the Chrysler Collision Detection (CCD) data bus. The CAB turns the lamp on or off based upon the results of the ABS self-tests. The CAB continually monitors the ABS circuits and sensors, including the brake warning switch and the ABS lamp, to decide whether the system is in good operating condition. The CAB then sends the proper messages to the instrument cluster on the CCD data bus to turn the lamp on or off. If the CAB turns the lamp on after the bulb test, it indicates that the CAB has detected a system malfunction. The parking brake switch is hard wired to the instrument cluster and closes to ground when the parking brake is applied. The brake warning switch is hard wired to the CAB and closes to ground when it senses unequal hydraulic pressures in the two halves of the split brake hydraulic system, possibly due to low brake fluid level or brake fluid leakage. After the bulb test, if the red brake warning lamp remains illuminated with the parking brake released, the base brake system may not be operational. The vehicle should never be operated while the red brake warning lamp is illuminated. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > General Information > Page 4434 Brake Warning Indicator: Description and Operation Brake Warning Lamp Description The red brake warning lamp is used to alert the driver of a hydraulic fault or that the parking brake is applied. For the RWAL system, the red brake warning lamp also is used to alerts the driver of a problem with the RWAL system. The brake warning lamp illuminates when a message is sent over the bus to the cluster to illuminate the bulb. A ground for the bulb is provided when: - The brakes are applied and the park brake switch is actuated. - A hydraulic fault has occurred and the pressure differential switch is actuated. - A RWAL fault has occurred. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Page 4435 Brake Warning Indicator: Testing and Inspection The diagnosis found here addresses an inoperative brake warning lamp condition. If the brake warning lamp stays on with the ignition switch in the On position and the parking brake released, or comes on while driving, WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the wire harness connector at the park brake switch. With the park brake released, check for continuity between the park brake switch terminal and a good ground. There should be no continuity If OK, go to Step 5. If not OK, adjust or replace the faulty park brake switch. 4. Remove the instrument cluster. With the park brake switch wire harness connector still unplugged, check for continuity between the park brake switch wire harness connector cavity and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the short circuit as required. 5. Check for continuity between the park brake switch sense circuit cavities of the instrument cluster wire harness connector (connector A) and the park brake switch wire harness connector, There should be continuity. If OK, see Instrument Cluster in the Diagnosis and Testing for further testing of the brake warning lamp and the instrument cluster circuitry. If not OK, repair the open circuit as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Piston Diameter LD 2.126 in Piston Diameter HD 2.205 in Mounting Bolts 24 ft.lb Adapter Bolts 210 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 4440 Brake Caliper: Testing and Inspection CLEANING Clean the caliper components with clean brake fluid or brake clean only. Wipe the caliper and piston dry with lint free towels or use low pressure compressed air. CAUTION: Do not use gasoline, kerosene, thinner, or similar solvents. These products may leave a residue that could damage the piston and seal. INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. Polishing Piston Bore The bore can be lightly polished with a brake hone to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. Raise and support vehicle. 2. Remove front wheel and tire assembly. Caliper 3. Remove caliper brake hose bolt, washers and hose. 4. Remove caliper mounting bolts. 5. Tilt the bottom of the caliper up and remove it from the adapter. 6. Remove anti-rattle springs. NOTE: Upper and lower anti-rattle springs are not interchangeable. INSTALLATION 1. Clean caliper mounting adapter and anti-rattle springs. Then lubricate anti-rattle springs and mounting bolts with Mopar high temperature or multi-mileage grease. 2. Install anti-rattle springs. 3. Tilt the top of the caliper over rotor and under adapter. Then push the bottom of the caliper down onto the adapter. 4. Install caliper mounting bolts and tighten to 33 Nm (24 ft. lbs.). 5. Install brake hose to caliper with new seal washers and tighten fitting bolt to 24 Nm (18 ft. lbs.). CAUTION: Be sure the front hose is free of kinks or bends and is clear of all chassis and suspension components. 6. Fill master cylinder with Mopar brake fluid or equivalent. 7. Fill and bleed brake system. 8. Install wheel and tire assembly and lower vehicle. 9. Apply brakes several times to seat caliper pistons and brake shoes. Be sure firm pedal is obtained before moving vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4443 Brake Caliper: Service and Repair Disassembly and Assembly DISASSEMBLY 1. Drain the brake fluid from caliper. C-Clamp One Piston 2. C-clamp a block of wood over one piston. Protect Caliper Piston 3. Take another piece of wood and pad it with one-inch thickness of shop towels. Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: Never attempt to catch the piston as it leaves the bore. This could result in personal injury. 5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using the same procedure with short bursts of low pressure air. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4444 Piston Dust Boot Removal 8. Remove piston dust boots with a suitable pry tool. Piston Seal 9. Remove piston seals from caliper. CAUTION: Do not scratch piston bore while removing the seals. Disc Brake Caliper 10. Push caliper mounting bolt bushings out of the boot seals and remove the boot seals from the caliper. 11. Remove caliper bleed screw. ASSEMBLY CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4445 1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid. Piston Seal 2. Install new piston seals into caliper bores. NOTE: Verify seal is fully seated and not twisted. 3. Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into the groove at the top of piston. 4. Stretch boot rearward to straighten boot folds, then move boot forward until folds snap into place. Caliper Piston Installation 5. Install piston into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle. Seating Dust Boot Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4446 6. Seat dust boot in caliper with Handle C-4171 or equivalent and Installer: - HD 56 mm caliper: Installer C-4340 - LD 54 mm caliper: Installer C-3716-A 7. Install the second piston and dust boot. 8. Lubricate caliper mounting bolt bushings, boot seals and bores with silicone grease. 9. Install the boot seals into the caliper seal bores and center the seals in the bores. 10. Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the bushing groves at either end of the bushing. 11. Install caliper bleed screw. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 inch) of the rivet heads. Bonded lining should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4450 Brake Pad: Service and Repair NOTE: If brake shoes are to be replaced, remove 1/4 of the fluid from master cylinder with suction gun. REMOVAL 1. Raise and support vehicle. 2. Remove front wheel and tire assemblies. 3. Remove caliper mounting bolts. Caliper 4. Remove caliper by tilting the bottom up and off the caliper adapter. NOTE: Do not allow brake hose to support caliper assembly. Inboard Brake Shoe 5. Remove inboard brake shoe from the caliper adapter. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4451 Outboard Brake Shoe 6. Remove outboard brake shoe from caliper adapter. Top Anti-Rattle Spring Bottom Anti-Rattle Spring 7. Remove the anti-rattle springs from the caliper adapter. INSTALLATION 1. Bottom pistons in caliper bore with C-clamp. Place an old brake shoe between a C-clamp and caliper piston. 2. Clean caliper adapter and anti-rattle springs. Then lubricate anti-rattle springs and mounting bolts with Mopar high temperature or multi-mileage Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4452 grease. 3. Install anti-rattle springs. NOTE: Anti-rattle springs are not interchangeable. 4. Install inboard brake shoe in adapter. 5. Install outboard brake shoe in adapter. 6. Tilt the top of the caliper over rotor and under adapter. Then push the bottom of the caliper down onto the adapter. 7. Install caliper mounting bolts and tighten to 33 Nm (24 ft. lbs.). 8. Install wheel and tire assemblies and lower vehicle. 9. Apply brakes several times to seat caliper pistons and brake shoes and obtain firm pedal. 10. Top off master cylinder fluid level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Disc Brake Rotor Type...................................................................................................................................................... ....................................................................Ventilated Diameter 1500/2500............................................................................................................................. .......................................................298 mm (11.75 in) Diameter 3500...................................................................................................................................... ....................................................325.6 mm (12.82 in) Max. Runout......................................................................................................................................... ....................................................0.102 mm (0.004 in) Max. Thickness Variation..................................................................................................................... .................................................0.013 mm (0.0005 in) Min. Thickness...................................................................................................................................... .....................................................30.0 mm (1.181 in) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4456 Brake Rotor/Disc: Testing and Inspection GENERAL INFORMATION The rotor braking surfaces should not be refinished unless necessary Light surface rust and scale can be removed with a lathe equipped with dual sanding discs. The rotor surfaces can be restored by machining in a disc brake lathe if surface scoring and wear are light. Replace the rotor under the following conditions: severely scored - tapered - hard spots - cracked - below minimum thickness ROTOR MINIMUM THICKNESS Measure rotor thickness at the center of the brake shoe contact surface. Replace the rotor if worn below minimum thickness, or if machining would reduce thickness below the allowable minimum. Rotor minimum thickness is usually specified on the rotor hub. The specification is either stamped or cast into the hub surface. ROTOR RUNOUT Checking Rotor Runout And Thickness Variation Check rotor lateral runout with dial indicator C-3339 or equivalent. Excessive lateral runout will cause brake pedal pulsation and rapid, uneven wear of the brake shoes. Position the dial indicator plunger approximately 25.4 min (1 inch) inward from the rotor edge. Maximum allowable rotor runout is 0.102 mm (0.004 inch). ROTOR THICKNESS VARIATION Variations in rotor thickness will cause pedal pulsation, noise and shudder. Measuring Rotor Thickness Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4457 Measure rotor thickness at 6 to 12 points around the rotor face. Position the micrometer approximately 25.4 mm (1 inch) from the rotor outer circumference for each measurement. Thickness should not vary by more than 0.013 mm (0.0005 inch) from point-to-point on the rotor. Machine or replace the rotor if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Rotor Removal and Installation Brake Rotor/Disc: Service and Repair Rotor Removal and Installation REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove caliper. NOTE: Do not allow brake hose to support caliper assembly. Caliper Adapter 4. Remove caliper adapter bolts from the steering knuckle and remove adapter. Disc Brake Rotor 5. Remove grease cap, cotter pin, nut lock, nut, washer and outer wheel bearing. 6. Remove the rotor from the spindle. INSTALLATION 1. Inspect and repack wheel bearings if necessary. Install new grease seals if inner bearing was removed. 2. On models with all-wheel antilock system (ABS), check condition of tone wheel in rotor hub. If teeth on wheel are damaged, rotor and hub assembly will have to be replaced (tone wheel is not serviced separately). 3. Install rotor on spindle. 4. Install outer bearing, thrust washer and nut. 5. Tighten wheel bearing adjusting nut to 27 - 34 Nm (240 - 300 inch lbs.) while turning rotor. 6. Loosen wheel bearing adjusting nut completely. Then retighten nut finger tight. Wheel bearing end play should not exceed 0.076 mm (0.003 inch) . 7. Install nut lock on bearing adjusting nut. Align lock slots with cotter pin hole and secure nut and lock with new cotter pin. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Rotor Removal and Installation > Page 4460 8. Clean grease cap and coat interior of cap with wheel bearing grease. 9. Install caliper adapter and tighten adapter bolts to: - LD 1500: 176 Nm (130 ft. lbs.) - HD 2500/3500: 285 Nm (210 ft. lbs.) 10. Install caliper and tighten bolts to 33 Nm (24 ft. lbs.). 11. Install wheel and tire assembly and lower vehicle. 12. Apply brakes several times to seat brake shoes. Be sure to obtain firm pedal before moving vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Rotor Removal and Installation > Page 4461 Brake Rotor/Disc: Service and Repair Rotor Refinishing Rotor braking surfaces can be sanded or machined in a disc brake lathe. Fig 6 Refacing Brake Disc The lathe must machine both sides of the rotor simultaneously with dual (two) cutter heads. Equipment capable of machining only one side at a time will produce a tapered rotor. Fig 7 Refacing Brake Disc -- Final Finish The lathe should also be equipped with a grinder attachment or dual sanding discs for final cleanup or light refinishing. If the rotor surfaces only need minor cleanup of rust, scale, or minor scoring, use abrasive discs to clean up the rotor surfaces. However, when a rotor is scored or worn, machining with cutting tools will be required. CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum allowable thickness. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications Bolts ..................................................................................................................................................... .................................................. 115 Nm (85 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 4466 Backing Plate: Service and Repair REMOVAL 1. Remove wheel and tire assembly and brake drum. 2. Remove brake shoe assembly. 3. Remove parking brake cable from parking brake lever. 4. Compress parking brake cable retainer tabs. Then push retainer and cable through and out of support plate. 5. Disconnect brake line at wheel cylinder. 6. Remove wheel cylinder from support plate. 7. Remove axle shaft, refer to Transmission and Drivetrain for procedures. 8. Remove bolts attaching support Plate to axle and remove support plate. INSTALLATION 1. Apply bead of silicone sealer around axle mounting surface of support plate. 2. Install support plate on axle flange. Tighten attaching bolts to 115 Nm (85 ft. lbs.). 3. Apply bead of silicone sealer around wheel cylinder mounting surface and install wheel cylinder. 4. Install brake line in wheel cylinder. 5. Install parking brake cable in support plate. 6. Install axle shaft, refer to Transmission and Drivetrain for procedure. 7. Connect parking brake cable to lever on secondary shoe and install brake shoes on support plate. 8. Adjust brake shoes to drum with brake gauge. 9. Install brake drum and wheel and tire assembly. 10. Bleed brake system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Customer Interest for Brake Drum: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application Technical Service Bulletin # 05-07-98 Date: 990201 Brakes - Vibration/Shudder on Application NO: 05-07-98 GROUP: Brakes DATE: Feb. 1, 1999 SUBJECT: Vehicle Vibrates/Shudders When Brakes Are Applied MODELS: 1998 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 250013500 RAM VANS EQUIPPED WITH THE 9.25 HD AXLE (SALES CODE DRG). SYMPTOM/CONDITION: Vehicle vibrates/shudders when the brakes are applied. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 03-20-01-94 Remove and Install Axle Shafts, Measure Drum Diameter and Runout, Adjust Rear Brakes, Adjust Parking Brake Brake 1.0 Hrs. Related Operations: NOTE: OPERATIONS INCLUDE REPLACING BRAKE DRUMS WHEN NECESSARY. 03-20-20-50 Replace Axle Bearing and Seal, Right Side 0.2 Hrs. 03-20-20-51 Replace Axle Bearing and Seal, Left Side 0.2 Hrs. 03-20-26-50 Replace Axle Seal, Right Side 0.1 Hrs. 03-20-26-51 Replace Axle Seal, Left Side 0.1 Hrs. 05-70-06-59 Replace Brake Shoes And Linings 0.4 Hrs. 05-20-26-51 Resurface One Brake Drum 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Customer Interest for Brake Drum: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4475 05-20-26-52 Resurface Both Brake Drums 0.7 Hrs. FAILURE CODE: P8 - New Part Diagnosis 1. Drive the vehicle at a safe speed and apply the service brakes. If the vehicle does not vibrate/shudder until the brakes are applied, proceed to the next step. If the vehicle vibrates/shudder regardless of service brake operation, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for noise and vibration diagnosis in Groups 02, 03, 05, 09, 11, 19, and 22. 2. Drive the vehicle at a safe speed in area free of traffic. Lightly apply the parking brake. If the vehicle vibrates/shudder while the parking brake is applied, proceed to the next step. If the vehicle does not vibrate/shudder while the parking brake is applied, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for front brake vibration diagnosis in Group 05. 3. Raise the vehicle on a suitable hoist. NOTE: MAKE SURE THE PARKING BRAKE IS NOT APPLIED PRIOR TO LIFTING THE VEHICLE ON A HOIST. 4. Remove both right and left rear tire/wheel assemblies. 5. Remove both right and left rear brake drums. 6. Using a 100 - 125 mm (4-5 in.) micrometer or vernier caliper, measure the diameter of the brake drum pilot on the axle shaft (Figure 1). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Customer Interest for Brake Drum: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4476 7. If the brake drum pilot is less than 122.7 mm (4.830 in.) (Figure 2), perform the Repair Procedure. If the brake drum pilot is equal to or greater than 122.7 mm (4.830 in.), refer to the 1998 Ram Van Service Manual (Publication No. 81-370- 8107), pages 5-5 through 5-11 for information regarding brake system Diagnosis and Testing. Repair Procedure This bulletin involves installing revised axle shafts and if necessary brake linings and drums. 1. Clean all foreign material from the axle housing cover area. 2. Position a drain pan under the axle housing cover area. 3. Loosen housing cover bolts. Drain the lubricant from the housing and axle shaft tubes. Remove the housing cover. 4. Remove the original sealant from the housing and cover surfaces then, clean the cover surfaces with Mopar Brake parts Cleaner p/n 04549623. 5. Rotate the differential case so that the pinion mate gear shaft lock screw is accessible. Remove the lock screw and pinion mate gear shaft from the differential case (Figure 3). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Customer Interest for Brake Drum: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4477 6. Push the axle shaft inward and remove the axle shaft C-clip lock from the axle shaft (Figure 4.). 7. Remove axle shaft. Use care to prevent damage to the axle shaft bearing and seal, which will remain in the axle shaft tube. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 8. Inspect the axle shaft seal for leakage or damage and inspect the roller bearing contact surface on axle shaft for signs of brinelling, galling, and/or pitting. Replace the seal and/or bearing as necessary using p/n 04137314 for the seal and p/n 04117858 for the bearing. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 3-20 and 3-21 for Axle Seal And Bearing service. 9. Lubricate bearing bore and seal lip with gear lubricant p/n 05010320AA. Insert the new axle shaft p/n 041 17897AB through the seal and bearing, then engage the axle shaft splines into the side gear splines. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 10. Insert the C-clip lock onto the end of the axle shaft. Push axle shaft outward to seat the C-clip lock in the side gear. 11. Perform Steps 6 through 10 to the other axle shaft. 12. Insert pinion mate shaft into differential case and through thrust washers and pinion gears. 13. Align the hole in the shaft with the hole in the differential case. Apply Lock & Seal Adhesive p/n 04318031 to the threads of the pinion mate shaft lock screw and install the lock screw into the differential case. Tighten the screw to 11 Nm (8 ft. lbs). 14. Apply a bead of Mopar Silicone Sealant p/n 82300234 to the housing cover (Figure 5). The silicone sealant must be applied to all mating surfaces of the cover including around the cover bolt holes. NOTE: INSTALL THE COVER WITHIN FIVE MINUTES AFTER APPLYING THE SEALANT. 15. Install the cover and any identification tag. Tighten the cover attaching bolts to 44 Nm (33 ft. lbs.). 16. Fill the differential with 2.32 L (4.9 pts.) of Mopar 75W/90 Gear Lubricant p/n 0501 0320AA. 17. Inspect the brake linings on both sides of the vehicle. Replace the brake linings as necessary using p/n 05003999AA. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-21 through 5-22 for Rear Brake Shoes - 12 1/8 inch Removal and Installation. Anytime brake linings are replaced, new brake adjusting lever pins p/n 03492671 must be installed. 18. Measure brake drum diameter and runout. Brake drum diameter must be checked using an accurate brake drum micrometer. The maximum allowable diameter of the drum braking surface is indicated on the drum outer edge. Brake drum runout must be checked by mounting the drum onto a brake lathe and checking variation using a dial indicator. Variation in drum diameter should not exceed 0.076 mm (0.003 in.). Drum runout should not exceed 0.20 mm (0.008 in.) out of round. If the drum exceeds the variation/runout specification but does not exceed the maximum allowable diameter, resurface the brake drum. If the brake drum exceeds the maximum allowable diameter, replace the brake drum with p/n 5200951 9AC. If the brake drum is less than the maximum allowable variation/runout and the diameter of the drum is less than the maximum specification and there is not any major scoring in the drum, the drum can be reused. 19. Adjust brake shoes to brake drum using a brake gauge. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Customer Interest for Brake Drum: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4478 and 5-30 for information regarding proper brake shoe adjustment. 20. Install the brake drum onto the vehicle. 21. Install the tire and wheels onto the vehicle. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 22-8 and 22-9 for proper tire/wheel installation. 22. Adjust the park brake cable tension. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-30 and 5-31 for information regarding proper parking brake cable tension adjustment. 23. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Drum: > 05-07-98 > Feb > 99 > Brakes Vibration/Shudder on Application Technical Service Bulletin # 05-07-98 Date: 990201 Brakes - Vibration/Shudder on Application NO: 05-07-98 GROUP: Brakes DATE: Feb. 1, 1999 SUBJECT: Vehicle Vibrates/Shudders When Brakes Are Applied MODELS: 1998 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 250013500 RAM VANS EQUIPPED WITH THE 9.25 HD AXLE (SALES CODE DRG). SYMPTOM/CONDITION: Vehicle vibrates/shudders when the brakes are applied. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 03-20-01-94 Remove and Install Axle Shafts, Measure Drum Diameter and Runout, Adjust Rear Brakes, Adjust Parking Brake Brake 1.0 Hrs. Related Operations: NOTE: OPERATIONS INCLUDE REPLACING BRAKE DRUMS WHEN NECESSARY. 03-20-20-50 Replace Axle Bearing and Seal, Right Side 0.2 Hrs. 03-20-20-51 Replace Axle Bearing and Seal, Left Side 0.2 Hrs. 03-20-26-50 Replace Axle Seal, Right Side 0.1 Hrs. 03-20-26-51 Replace Axle Seal, Left Side 0.1 Hrs. 05-70-06-59 Replace Brake Shoes And Linings 0.4 Hrs. 05-20-26-51 Resurface One Brake Drum 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Drum: > 05-07-98 > Feb > 99 > Brakes Vibration/Shudder on Application > Page 4484 05-20-26-52 Resurface Both Brake Drums 0.7 Hrs. FAILURE CODE: P8 - New Part Diagnosis 1. Drive the vehicle at a safe speed and apply the service brakes. If the vehicle does not vibrate/shudder until the brakes are applied, proceed to the next step. If the vehicle vibrates/shudder regardless of service brake operation, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for noise and vibration diagnosis in Groups 02, 03, 05, 09, 11, 19, and 22. 2. Drive the vehicle at a safe speed in area free of traffic. Lightly apply the parking brake. If the vehicle vibrates/shudder while the parking brake is applied, proceed to the next step. If the vehicle does not vibrate/shudder while the parking brake is applied, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for front brake vibration diagnosis in Group 05. 3. Raise the vehicle on a suitable hoist. NOTE: MAKE SURE THE PARKING BRAKE IS NOT APPLIED PRIOR TO LIFTING THE VEHICLE ON A HOIST. 4. Remove both right and left rear tire/wheel assemblies. 5. Remove both right and left rear brake drums. 6. Using a 100 - 125 mm (4-5 in.) micrometer or vernier caliper, measure the diameter of the brake drum pilot on the axle shaft (Figure 1). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Drum: > 05-07-98 > Feb > 99 > Brakes Vibration/Shudder on Application > Page 4485 7. If the brake drum pilot is less than 122.7 mm (4.830 in.) (Figure 2), perform the Repair Procedure. If the brake drum pilot is equal to or greater than 122.7 mm (4.830 in.), refer to the 1998 Ram Van Service Manual (Publication No. 81-370- 8107), pages 5-5 through 5-11 for information regarding brake system Diagnosis and Testing. Repair Procedure This bulletin involves installing revised axle shafts and if necessary brake linings and drums. 1. Clean all foreign material from the axle housing cover area. 2. Position a drain pan under the axle housing cover area. 3. Loosen housing cover bolts. Drain the lubricant from the housing and axle shaft tubes. Remove the housing cover. 4. Remove the original sealant from the housing and cover surfaces then, clean the cover surfaces with Mopar Brake parts Cleaner p/n 04549623. 5. Rotate the differential case so that the pinion mate gear shaft lock screw is accessible. Remove the lock screw and pinion mate gear shaft from the differential case (Figure 3). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Drum: > 05-07-98 > Feb > 99 > Brakes Vibration/Shudder on Application > Page 4486 6. Push the axle shaft inward and remove the axle shaft C-clip lock from the axle shaft (Figure 4.). 7. Remove axle shaft. Use care to prevent damage to the axle shaft bearing and seal, which will remain in the axle shaft tube. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 8. Inspect the axle shaft seal for leakage or damage and inspect the roller bearing contact surface on axle shaft for signs of brinelling, galling, and/or pitting. Replace the seal and/or bearing as necessary using p/n 04137314 for the seal and p/n 04117858 for the bearing. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 3-20 and 3-21 for Axle Seal And Bearing service. 9. Lubricate bearing bore and seal lip with gear lubricant p/n 05010320AA. Insert the new axle shaft p/n 041 17897AB through the seal and bearing, then engage the axle shaft splines into the side gear splines. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 10. Insert the C-clip lock onto the end of the axle shaft. Push axle shaft outward to seat the C-clip lock in the side gear. 11. Perform Steps 6 through 10 to the other axle shaft. 12. Insert pinion mate shaft into differential case and through thrust washers and pinion gears. 13. Align the hole in the shaft with the hole in the differential case. Apply Lock & Seal Adhesive p/n 04318031 to the threads of the pinion mate shaft lock screw and install the lock screw into the differential case. Tighten the screw to 11 Nm (8 ft. lbs). 14. Apply a bead of Mopar Silicone Sealant p/n 82300234 to the housing cover (Figure 5). The silicone sealant must be applied to all mating surfaces of the cover including around the cover bolt holes. NOTE: INSTALL THE COVER WITHIN FIVE MINUTES AFTER APPLYING THE SEALANT. 15. Install the cover and any identification tag. Tighten the cover attaching bolts to 44 Nm (33 ft. lbs.). 16. Fill the differential with 2.32 L (4.9 pts.) of Mopar 75W/90 Gear Lubricant p/n 0501 0320AA. 17. Inspect the brake linings on both sides of the vehicle. Replace the brake linings as necessary using p/n 05003999AA. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-21 through 5-22 for Rear Brake Shoes - 12 1/8 inch Removal and Installation. Anytime brake linings are replaced, new brake adjusting lever pins p/n 03492671 must be installed. 18. Measure brake drum diameter and runout. Brake drum diameter must be checked using an accurate brake drum micrometer. The maximum allowable diameter of the drum braking surface is indicated on the drum outer edge. Brake drum runout must be checked by mounting the drum onto a brake lathe and checking variation using a dial indicator. Variation in drum diameter should not exceed 0.076 mm (0.003 in.). Drum runout should not exceed 0.20 mm (0.008 in.) out of round. If the drum exceeds the variation/runout specification but does not exceed the maximum allowable diameter, resurface the brake drum. If the brake drum exceeds the maximum allowable diameter, replace the brake drum with p/n 5200951 9AC. If the brake drum is less than the maximum allowable variation/runout and the diameter of the drum is less than the maximum specification and there is not any major scoring in the drum, the drum can be reused. 19. Adjust brake shoes to brake drum using a brake gauge. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Drum: > 05-07-98 > Feb > 99 > Brakes Vibration/Shudder on Application > Page 4487 and 5-30 for information regarding proper brake shoe adjustment. 20. Install the brake drum onto the vehicle. 21. Install the tire and wheels onto the vehicle. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 22-8 and 22-9 for proper tire/wheel installation. 22. Adjust the park brake cable tension. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-30 and 5-31 for information regarding proper parking brake cable tension adjustment. 23. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Page 4488 Brake Drum: Specifications Rear Drum Specifications 11" Rear Drum Nominal Diameter ................................................................................................................................ ........................................................... 11.030" Maximum Machine Limit ...................................................................................................................... .......................................................... 11.090" Discard Diameter ................................................................................................................................. ...................................................................... * Runout Limit ........................................................................................................................................ ............................................................. 0.008" 12" Rear Drum Nominal Diameter ................................................................................................................................ ........................................................... 12.125" Maximum Machine Limit ...................................................................................................................... .......................................................... 12.185" Discard Diameter ................................................................................................................................. ...................................................................... * Runout Limit ........................................................................................................................................ ............................................................. 0.008" * - Discard when diameter is greater than Maximum Machine Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Page 4489 Brake Drum: Testing and Inspection GENERAL INFORMATION The maximum allowable diameter of the drum braking surface is indicated on the drum outer edge. Generally, a drum can be machined to a maximum of 1.52 mm (0.060 inch) oversize. Always replace the drum if machining would cause drum diameter to exceed the size limit indicated on the drum. BRAKE DRUM RUNOUT Measure drum diameter and runout with an accurate gauge. The most accurate method of measurement involves mounting the drum in a brake lathe and checking variation and runout with a dial indicator. Variations in drum diameter should not exceed 0.076 mm (0.003 inch). Drum runout should not exceed 0.20 mm (0.008 inch) out of round. Machine the drum if runout or variation exceed these values. Replace the drum if machining causes the drum to exceed the maximum allowable diameter. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest for Brake Shoe: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application Technical Service Bulletin # 05-07-98 Date: 990201 Brakes - Vibration/Shudder on Application NO: 05-07-98 GROUP: Brakes DATE: Feb. 1, 1999 SUBJECT: Vehicle Vibrates/Shudders When Brakes Are Applied MODELS: 1998 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 250013500 RAM VANS EQUIPPED WITH THE 9.25 HD AXLE (SALES CODE DRG). SYMPTOM/CONDITION: Vehicle vibrates/shudders when the brakes are applied. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 03-20-01-94 Remove and Install Axle Shafts, Measure Drum Diameter and Runout, Adjust Rear Brakes, Adjust Parking Brake Brake 1.0 Hrs. Related Operations: NOTE: OPERATIONS INCLUDE REPLACING BRAKE DRUMS WHEN NECESSARY. 03-20-20-50 Replace Axle Bearing and Seal, Right Side 0.2 Hrs. 03-20-20-51 Replace Axle Bearing and Seal, Left Side 0.2 Hrs. 03-20-26-50 Replace Axle Seal, Right Side 0.1 Hrs. 03-20-26-51 Replace Axle Seal, Left Side 0.1 Hrs. 05-70-06-59 Replace Brake Shoes And Linings 0.4 Hrs. 05-20-26-51 Resurface One Brake Drum 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest for Brake Shoe: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4498 05-20-26-52 Resurface Both Brake Drums 0.7 Hrs. FAILURE CODE: P8 - New Part Diagnosis 1. Drive the vehicle at a safe speed and apply the service brakes. If the vehicle does not vibrate/shudder until the brakes are applied, proceed to the next step. If the vehicle vibrates/shudder regardless of service brake operation, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for noise and vibration diagnosis in Groups 02, 03, 05, 09, 11, 19, and 22. 2. Drive the vehicle at a safe speed in area free of traffic. Lightly apply the parking brake. If the vehicle vibrates/shudder while the parking brake is applied, proceed to the next step. If the vehicle does not vibrate/shudder while the parking brake is applied, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for front brake vibration diagnosis in Group 05. 3. Raise the vehicle on a suitable hoist. NOTE: MAKE SURE THE PARKING BRAKE IS NOT APPLIED PRIOR TO LIFTING THE VEHICLE ON A HOIST. 4. Remove both right and left rear tire/wheel assemblies. 5. Remove both right and left rear brake drums. 6. Using a 100 - 125 mm (4-5 in.) micrometer or vernier caliper, measure the diameter of the brake drum pilot on the axle shaft (Figure 1). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest for Brake Shoe: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4499 7. If the brake drum pilot is less than 122.7 mm (4.830 in.) (Figure 2), perform the Repair Procedure. If the brake drum pilot is equal to or greater than 122.7 mm (4.830 in.), refer to the 1998 Ram Van Service Manual (Publication No. 81-370- 8107), pages 5-5 through 5-11 for information regarding brake system Diagnosis and Testing. Repair Procedure This bulletin involves installing revised axle shafts and if necessary brake linings and drums. 1. Clean all foreign material from the axle housing cover area. 2. Position a drain pan under the axle housing cover area. 3. Loosen housing cover bolts. Drain the lubricant from the housing and axle shaft tubes. Remove the housing cover. 4. Remove the original sealant from the housing and cover surfaces then, clean the cover surfaces with Mopar Brake parts Cleaner p/n 04549623. 5. Rotate the differential case so that the pinion mate gear shaft lock screw is accessible. Remove the lock screw and pinion mate gear shaft from the differential case (Figure 3). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest for Brake Shoe: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4500 6. Push the axle shaft inward and remove the axle shaft C-clip lock from the axle shaft (Figure 4.). 7. Remove axle shaft. Use care to prevent damage to the axle shaft bearing and seal, which will remain in the axle shaft tube. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 8. Inspect the axle shaft seal for leakage or damage and inspect the roller bearing contact surface on axle shaft for signs of brinelling, galling, and/or pitting. Replace the seal and/or bearing as necessary using p/n 04137314 for the seal and p/n 04117858 for the bearing. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 3-20 and 3-21 for Axle Seal And Bearing service. 9. Lubricate bearing bore and seal lip with gear lubricant p/n 05010320AA. Insert the new axle shaft p/n 041 17897AB through the seal and bearing, then engage the axle shaft splines into the side gear splines. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 10. Insert the C-clip lock onto the end of the axle shaft. Push axle shaft outward to seat the C-clip lock in the side gear. 11. Perform Steps 6 through 10 to the other axle shaft. 12. Insert pinion mate shaft into differential case and through thrust washers and pinion gears. 13. Align the hole in the shaft with the hole in the differential case. Apply Lock & Seal Adhesive p/n 04318031 to the threads of the pinion mate shaft lock screw and install the lock screw into the differential case. Tighten the screw to 11 Nm (8 ft. lbs). 14. Apply a bead of Mopar Silicone Sealant p/n 82300234 to the housing cover (Figure 5). The silicone sealant must be applied to all mating surfaces of the cover including around the cover bolt holes. NOTE: INSTALL THE COVER WITHIN FIVE MINUTES AFTER APPLYING THE SEALANT. 15. Install the cover and any identification tag. Tighten the cover attaching bolts to 44 Nm (33 ft. lbs.). 16. Fill the differential with 2.32 L (4.9 pts.) of Mopar 75W/90 Gear Lubricant p/n 0501 0320AA. 17. Inspect the brake linings on both sides of the vehicle. Replace the brake linings as necessary using p/n 05003999AA. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-21 through 5-22 for Rear Brake Shoes - 12 1/8 inch Removal and Installation. Anytime brake linings are replaced, new brake adjusting lever pins p/n 03492671 must be installed. 18. Measure brake drum diameter and runout. Brake drum diameter must be checked using an accurate brake drum micrometer. The maximum allowable diameter of the drum braking surface is indicated on the drum outer edge. Brake drum runout must be checked by mounting the drum onto a brake lathe and checking variation using a dial indicator. Variation in drum diameter should not exceed 0.076 mm (0.003 in.). Drum runout should not exceed 0.20 mm (0.008 in.) out of round. If the drum exceeds the variation/runout specification but does not exceed the maximum allowable diameter, resurface the brake drum. If the brake drum exceeds the maximum allowable diameter, replace the brake drum with p/n 5200951 9AC. If the brake drum is less than the maximum allowable variation/runout and the diameter of the drum is less than the maximum specification and there is not any major scoring in the drum, the drum can be reused. 19. Adjust brake shoes to brake drum using a brake gauge. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest for Brake Shoe: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4501 and 5-30 for information regarding proper brake shoe adjustment. 20. Install the brake drum onto the vehicle. 21. Install the tire and wheels onto the vehicle. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 22-8 and 22-9 for proper tire/wheel installation. 22. Adjust the park brake cable tension. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-30 and 5-31 for information regarding proper parking brake cable tension adjustment. 23. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 05-07-98 > Feb > 99 > Brakes Vibration/Shudder on Application Technical Service Bulletin # 05-07-98 Date: 990201 Brakes - Vibration/Shudder on Application NO: 05-07-98 GROUP: Brakes DATE: Feb. 1, 1999 SUBJECT: Vehicle Vibrates/Shudders When Brakes Are Applied MODELS: 1998 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 250013500 RAM VANS EQUIPPED WITH THE 9.25 HD AXLE (SALES CODE DRG). SYMPTOM/CONDITION: Vehicle vibrates/shudders when the brakes are applied. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 03-20-01-94 Remove and Install Axle Shafts, Measure Drum Diameter and Runout, Adjust Rear Brakes, Adjust Parking Brake Brake 1.0 Hrs. Related Operations: NOTE: OPERATIONS INCLUDE REPLACING BRAKE DRUMS WHEN NECESSARY. 03-20-20-50 Replace Axle Bearing and Seal, Right Side 0.2 Hrs. 03-20-20-51 Replace Axle Bearing and Seal, Left Side 0.2 Hrs. 03-20-26-50 Replace Axle Seal, Right Side 0.1 Hrs. 03-20-26-51 Replace Axle Seal, Left Side 0.1 Hrs. 05-70-06-59 Replace Brake Shoes And Linings 0.4 Hrs. 05-20-26-51 Resurface One Brake Drum 0.4 Hrs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 05-07-98 > Feb > 99 > Brakes Vibration/Shudder on Application > Page 4507 05-20-26-52 Resurface Both Brake Drums 0.7 Hrs. FAILURE CODE: P8 - New Part Diagnosis 1. Drive the vehicle at a safe speed and apply the service brakes. If the vehicle does not vibrate/shudder until the brakes are applied, proceed to the next step. If the vehicle vibrates/shudder regardless of service brake operation, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for noise and vibration diagnosis in Groups 02, 03, 05, 09, 11, 19, and 22. 2. Drive the vehicle at a safe speed in area free of traffic. Lightly apply the parking brake. If the vehicle vibrates/shudder while the parking brake is applied, proceed to the next step. If the vehicle does not vibrate/shudder while the parking brake is applied, refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107) for front brake vibration diagnosis in Group 05. 3. Raise the vehicle on a suitable hoist. NOTE: MAKE SURE THE PARKING BRAKE IS NOT APPLIED PRIOR TO LIFTING THE VEHICLE ON A HOIST. 4. Remove both right and left rear tire/wheel assemblies. 5. Remove both right and left rear brake drums. 6. Using a 100 - 125 mm (4-5 in.) micrometer or vernier caliper, measure the diameter of the brake drum pilot on the axle shaft (Figure 1). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 05-07-98 > Feb > 99 > Brakes Vibration/Shudder on Application > Page 4508 7. If the brake drum pilot is less than 122.7 mm (4.830 in.) (Figure 2), perform the Repair Procedure. If the brake drum pilot is equal to or greater than 122.7 mm (4.830 in.), refer to the 1998 Ram Van Service Manual (Publication No. 81-370- 8107), pages 5-5 through 5-11 for information regarding brake system Diagnosis and Testing. Repair Procedure This bulletin involves installing revised axle shafts and if necessary brake linings and drums. 1. Clean all foreign material from the axle housing cover area. 2. Position a drain pan under the axle housing cover area. 3. Loosen housing cover bolts. Drain the lubricant from the housing and axle shaft tubes. Remove the housing cover. 4. Remove the original sealant from the housing and cover surfaces then, clean the cover surfaces with Mopar Brake parts Cleaner p/n 04549623. 5. Rotate the differential case so that the pinion mate gear shaft lock screw is accessible. Remove the lock screw and pinion mate gear shaft from the differential case (Figure 3). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 05-07-98 > Feb > 99 > Brakes Vibration/Shudder on Application > Page 4509 6. Push the axle shaft inward and remove the axle shaft C-clip lock from the axle shaft (Figure 4.). 7. Remove axle shaft. Use care to prevent damage to the axle shaft bearing and seal, which will remain in the axle shaft tube. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 8. Inspect the axle shaft seal for leakage or damage and inspect the roller bearing contact surface on axle shaft for signs of brinelling, galling, and/or pitting. Replace the seal and/or bearing as necessary using p/n 04137314 for the seal and p/n 04117858 for the bearing. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 3-20 and 3-21 for Axle Seal And Bearing service. 9. Lubricate bearing bore and seal lip with gear lubricant p/n 05010320AA. Insert the new axle shaft p/n 041 17897AB through the seal and bearing, then engage the axle shaft splines into the side gear splines. CAUTION: USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT SEAL LIP. 10. Insert the C-clip lock onto the end of the axle shaft. Push axle shaft outward to seat the C-clip lock in the side gear. 11. Perform Steps 6 through 10 to the other axle shaft. 12. Insert pinion mate shaft into differential case and through thrust washers and pinion gears. 13. Align the hole in the shaft with the hole in the differential case. Apply Lock & Seal Adhesive p/n 04318031 to the threads of the pinion mate shaft lock screw and install the lock screw into the differential case. Tighten the screw to 11 Nm (8 ft. lbs). 14. Apply a bead of Mopar Silicone Sealant p/n 82300234 to the housing cover (Figure 5). The silicone sealant must be applied to all mating surfaces of the cover including around the cover bolt holes. NOTE: INSTALL THE COVER WITHIN FIVE MINUTES AFTER APPLYING THE SEALANT. 15. Install the cover and any identification tag. Tighten the cover attaching bolts to 44 Nm (33 ft. lbs.). 16. Fill the differential with 2.32 L (4.9 pts.) of Mopar 75W/90 Gear Lubricant p/n 0501 0320AA. 17. Inspect the brake linings on both sides of the vehicle. Replace the brake linings as necessary using p/n 05003999AA. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-21 through 5-22 for Rear Brake Shoes - 12 1/8 inch Removal and Installation. Anytime brake linings are replaced, new brake adjusting lever pins p/n 03492671 must be installed. 18. Measure brake drum diameter and runout. Brake drum diameter must be checked using an accurate brake drum micrometer. The maximum allowable diameter of the drum braking surface is indicated on the drum outer edge. Brake drum runout must be checked by mounting the drum onto a brake lathe and checking variation using a dial indicator. Variation in drum diameter should not exceed 0.076 mm (0.003 in.). Drum runout should not exceed 0.20 mm (0.008 in.) out of round. If the drum exceeds the variation/runout specification but does not exceed the maximum allowable diameter, resurface the brake drum. If the brake drum exceeds the maximum allowable diameter, replace the brake drum with p/n 5200951 9AC. If the brake drum is less than the maximum allowable variation/runout and the diameter of the drum is less than the maximum specification and there is not any major scoring in the drum, the drum can be reused. 19. Adjust brake shoes to brake drum using a brake gauge. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 05-07-98 > Feb > 99 > Brakes Vibration/Shudder on Application > Page 4510 and 5-30 for information regarding proper brake shoe adjustment. 20. Install the brake drum onto the vehicle. 21. Install the tire and wheels onto the vehicle. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 22-8 and 22-9 for proper tire/wheel installation. 22. Adjust the park brake cable tension. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107), pages 5-30 and 5-31 for information regarding proper parking brake cable tension adjustment. 23. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 4511 Brake Shoe: Specifications As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 inch) of the rivet heads. Bonded linings should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 4512 Brake Shoe: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove clip nuts securing brake drum to wheel studs. 4. Remove brake drum. 5. Vacuum brake components to remove brake lining dust. 6. Unhook adjusting lever return spring from lever. 7. Remove lever and return spring from lever pivot pin. 8. Unhook adjuster lever from adjuster cable assembly. 9. Remove shoe-to-shoe upper spring. 10. Remove shoe hold-down springs. 11. Disconnect parking brake cable from parking brake lever. 12. Remove lower spring and adjuster assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 4513 13. Remove brake shoes. INSTALLATION NOTE: Pivot screw and adjusting nut have left hand threads on left side brake and right hand threads on right side brake. Verify that adjusting nuts are installed on correct side of vehicle. 1. Coat contact pads on support plate with Mopar high temperature grease, multi-mileage grease, or equivalent. 2. Assemble adjuster, lower spring and tooth brake shoes. Then position the assembled components on the support plate. NOTE: Primary shoe is installed toward the front of the vehicle and secondary toward the rear of the vehicle. 3. Install brake shoe hold-down springs and pins. Be sure hold-down pins are seated in support plate and springs are connected. 4. Insert parking brake cable through parking brake cable guide spring to parking brake lever. Be sure cable end is properly secured in lever. 5. Install upper spring. 6. Position adjuster lever return spring on pivot. 7. Install adjuster lever. 8. Attach adjuster cable to adjuster lever. Be sure cable is properly routed. 9. Adjust brake shoes to drum with brake gauge. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Bolts/Nuts 15 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 4517 Wheel Cylinder Components-Typical Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation REMOVAL 1. Remove wheel and tire assembly. 2. Remove brake drum. 3. Disconnect wheel cylinder brake line. 4. Remove brake shoe return springs and move shoes out of engagement with cylinder push rods. 5. Remove cylinder attaching bolts and remove cylinder from support plate. INSTALLATION 1. Apply bead of silicone sealer around cylinder mounting surface of support plate. 2. Install cylinder mounting bolts and tighten to 20 Nm (15 ft. lbs.). 3. Connect brake line to cylinder. 4. Install brake shoe return spring. 5. Install brake drum. 6. Install wheel and tire assembly. 7. Bleed brake system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4520 Wheel Cylinder: Service and Repair Cleaning and Inspection CLEANING Clean the cylinder and pistons with clean brake fluid or brake cleaner only. Do not use any other cleaning agents. Dry the cylinder and pistons with compressed air. Do not use rags or shop towels to dry the cylinder components. Lint from cloth material will adhere to the cylinder bores and pistons. INSPECTION Inspect the cylinder bore. Light discoloration and dark stains in the bore are normal and will not impair cylinder operation. The cylinder bore can be lightly polished but only with crocus cloth. Replace the cylinder if the bore is scored, pitted or heavily corroded. Honing the bore to restore the surface is not recommended. Inspect the cylinder pistons. The piston surfaces should be smooth and free of scratches, scoring and corrosion. Replace the pistons if worn, scored, or corroded. Do attempt to restore the surface by sanding or polishing. Discard the old piston cups and the spring and expander. These parts are not reusable. The original dust boots may be reused but only if they are in good condition. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4521 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul DISASSEMBLY 1. Remove push rods and boots. 2. Press pistons, cups and spring and expander out of cylinder bore. 3. Remove bleed screw. ASSEMBLY 1. Lubricate wheel cylinder bore, pistons, piston cups and spring and expander with clean brake fluid. 2. Install first piston in cylinder bore. Then install first cup in bore and against piston. Be sure lip of piston cup is facing inward (toward spring and expander) and flat side is against piston. 3. Install spring and expander followed by remaining piston cup and piston. 4. Install boots on each end of cylinder and insert push rods in boots. 5. Install cylinder bleed screw. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures W/ Four Wheel Antilock Brakes ABS system bleeding requires conventional bleeding methods plus use of the DRB scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. W/ Rear Wheel Antilock Brakes GENERAL INFORMATION RWAL brake bleeding can be performed manually, or with pressure bleeding equipment. Use Mopar DOT 3 brake fluid, or an equivalent meeting SAE J1703-F and DOT 3 standards, to fill and bleed the brake system. Bleed only one brake component at a time. Recommended bleed sequence is: master cylinder - combination valve - rear antilock valve - left rear wheel - right rear wheel - right front wheel - left front wheel MANUAL BLEEDING Use a bleed hose at each caliper/cylinder bleed screw. Attach one end of the hose to the bleed screw and insert the opposite end in glass container partially filled with brake fluid. A glass container makes it easier to see air bubbles as they exit the bleed hose. Be sure the end of the bleed hose remains immersed in fluid. This prevents air from being drawn back into the system. Do not allow the master cylinder to run out of fluid when bleeding the brakes. An empty cylinder will allow air to be drawn back into the system. Check fluid level frequently during bleeding operations. Be sure to tighten each brake line fitting, or bleed screw once bleeding is completed. Loose fittings and bleed screws allows air to enter the system. PRESSURE BLEEDING If pressure bleeding equipment will be used, the front brake metering valve will have to be held open to bleed the front brakes. The valve stem is located in the forward end of the combination valve. The stem must either be pressed inward, or held outward slightly. a spring clip tool or helper is needed to hold the valve stem in position. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15 - 20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4527 Brake Bleeding: Service and Repair Base Brake System Bleeding GENERAL INFORMATION Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. Bleed only one brake component at a time in the following sequence: master cylinder - combination valve - right rear wheel - left rear wheel - right front wheel - left front wheel MANUAL BLEEDING 1. Remove reservoir filler caps and fill reservoir with Mopar, or equivalent quality DOT 3 brake fluid. 2. If calipers, or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. Bleed Hose Setup 3. Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. PRESSURE BLEEDING Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15 - 20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Use adapter provided with the equipment or Adapter 6921 or equivalent. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Piston Diameter LD 2.126 in Piston Diameter HD 2.205 in Mounting Bolts 24 ft.lb Adapter Bolts 210 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 4531 Brake Caliper: Testing and Inspection CLEANING Clean the caliper components with clean brake fluid or brake clean only. Wipe the caliper and piston dry with lint free towels or use low pressure compressed air. CAUTION: Do not use gasoline, kerosene, thinner, or similar solvents. These products may leave a residue that could damage the piston and seal. INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. Polishing Piston Bore The bore can be lightly polished with a brake hone to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. Raise and support vehicle. 2. Remove front wheel and tire assembly. Caliper 3. Remove caliper brake hose bolt, washers and hose. 4. Remove caliper mounting bolts. 5. Tilt the bottom of the caliper up and remove it from the adapter. 6. Remove anti-rattle springs. NOTE: Upper and lower anti-rattle springs are not interchangeable. INSTALLATION 1. Clean caliper mounting adapter and anti-rattle springs. Then lubricate anti-rattle springs and mounting bolts with Mopar high temperature or multi-mileage grease. 2. Install anti-rattle springs. 3. Tilt the top of the caliper over rotor and under adapter. Then push the bottom of the caliper down onto the adapter. 4. Install caliper mounting bolts and tighten to 33 Nm (24 ft. lbs.). 5. Install brake hose to caliper with new seal washers and tighten fitting bolt to 24 Nm (18 ft. lbs.). CAUTION: Be sure the front hose is free of kinks or bends and is clear of all chassis and suspension components. 6. Fill master cylinder with Mopar brake fluid or equivalent. 7. Fill and bleed brake system. 8. Install wheel and tire assembly and lower vehicle. 9. Apply brakes several times to seat caliper pistons and brake shoes. Be sure firm pedal is obtained before moving vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4534 Brake Caliper: Service and Repair Disassembly and Assembly DISASSEMBLY 1. Drain the brake fluid from caliper. C-Clamp One Piston 2. C-clamp a block of wood over one piston. Protect Caliper Piston 3. Take another piece of wood and pad it with one-inch thickness of shop towels. Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: Never attempt to catch the piston as it leaves the bore. This could result in personal injury. 5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using the same procedure with short bursts of low pressure air. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4535 Piston Dust Boot Removal 8. Remove piston dust boots with a suitable pry tool. Piston Seal 9. Remove piston seals from caliper. CAUTION: Do not scratch piston bore while removing the seals. Disc Brake Caliper 10. Push caliper mounting bolt bushings out of the boot seals and remove the boot seals from the caliper. 11. Remove caliper bleed screw. ASSEMBLY CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4536 1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid. Piston Seal 2. Install new piston seals into caliper bores. NOTE: Verify seal is fully seated and not twisted. 3. Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into the groove at the top of piston. 4. Stretch boot rearward to straighten boot folds, then move boot forward until folds snap into place. Caliper Piston Installation 5. Install piston into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle. Seating Dust Boot Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4537 6. Seat dust boot in caliper with Handle C-4171 or equivalent and Installer: - HD 56 mm caliper: Installer C-4340 - LD 54 mm caliper: Installer C-3716-A 7. Install the second piston and dust boot. 8. Lubricate caliper mounting bolt bushings, boot seals and bores with silicone grease. 9. Install the boot seals into the caliper seal bores and center the seals in the bores. 10. Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the bushing groves at either end of the bushing. 11. Install caliper bleed screw. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4541 Brake Fluid: Testing and Inspection CAUTION: The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid. This includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS hydraulic control unit (HCU), and all hydraulic fluid hoses. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4542 Brake Fluid: Service and Repair Always clean the master cylinder filler caps before checking fluid level. If not cleaned, dirt from the caps could enter the fluid. Correct fluid level is to the bottom of the ring indicators on the reservoir. If necessary, add fluid to correct the level. With disc brake equipped vehicles, fluid level in the front brake reservoir will decrease slightly in proportion to normal lining wear. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation Brake Hose/Line: Description and Operation Flexible rubber hose is used at both front brakes and at the rear axle junction block. Double walled steel tubing is used to connect the master cylinder to the major hydraulic braking components and then to he flexible rubber hoses. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Page 4546 Brake Hose/Line: Testing and Inspection Flexible rubber hose is used at both front brakes and at the rear axle junction block. Inspect the hoses whenever the brake system is serviced, at every engine oil change, or whenever the vehicle is in for service. Inspect the hoses for surface cracking, scuffing, or worn spots. Replace any brake hose immediately if the fabric casing of the hose is exposed due to cracks or abrasions. Also check brake hose installation. Faulty installation can result in kinked, twisted hoses, or contact with the wheels and tires or other chassis components. All of these conditions can lead to scuffing, cracking and eventual failure. The steel brake lines should be inspected periodically for evidence of corrosion, twists, kinks, leaks, or other damage. Heavily corroded lines will eventually rust through causing leaks. In any case, corroded or damaged brake lines should be replaced. Factory replacement brake lines and hoses are recommended to ensure quality, correct length and superior fatigue life. Care should be taken to make sure that brake line and hose mating surfaces are clean and free from nicks and burrs. Also remember that right and left brake hoses are not interchangeable. Use new copper seal washers at all caliper connections. Be sure brake line connections are properly made (not cross threaded) and tightened to recommended torque. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Page 4547 Brake Hose/Line: Service and Repair GENERAL INFORMATION Mopar preformed metal brake line is recommended and preferred for all repairs. However, double-wall steel line can be used for emergency repair when factory replacement parts are not readily available. Inverted Flare And ISO Flare Special, heavy duty tube bending and flaring equipment is required to prepare double wall brake line. Special bending tools are needed to avoid kinking or twisting metal brake line. In addition, special flaring tools are needed for a double inverted flare/ISO flare. DOUBLE INVERTED FLARING 1. Cut off damaged tube with Tubing Cutter. 2. Ream cut edges of tubing to ensure proper flare. 3. Install replacement tube nut on the tube. 4. Insert tube in flaring tool. 5. Place gauge form over the end of the tube. 6. Push tubing through flaring tool jaws until tube contacts recessed notch in gauge that matches tube diameter. 7. Tighten the tool bar on the tube Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Page 4548 Cutting And Flaring Of Brake Fluid Tubing 8. Insert plug on gauge in the tube. Then swing compression disc over gauge and center tapered flaring screw in recess of compression disc. 9. Tighten tool handle until plug gauge is squarely seated on jaws of flaring tool. This will start the inverted flare. 10. Remove the plug gauge and complete the inverted flare. ISO FLARING To make a ISO flare use Snap-On Flaring Tool TFM-428 or equivalent. 1. Cut off damaged tube with Tubing Cutter. 2. Remove any burrs from the inside of the tube. 3. Install tube nut on the tube. 4. Position the tube in the flaring tool flush with the top of the tool bar. Then tighten the tool bar on the tube. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Page 4549 5. Install the correct size adaptor on the flaring tool yoke screw. 6. Lubricate the adaptor. 7. Align the adaptor and yoke screw over the tube. 8. Turn the yoke screw in until the adaptor is squarely seated on the tool bar. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation Brake Proportioning/Combination Valve: Description and Operation GENERAL INFORMATION The combination valve contains a pressure differential valve and switch, metering valve and a proportioning valve on 1500 models. The combination valve/ rear brake proportioning valve are not repairable and must be replaced as an assembly. PRESSURE DIFFERENTIAL SWITCH The pressure differential switch is connected to the brake warning lamp. The switch is triggered by movement of the switch valve. The purpose of the switch is to monitor fluid pressure in the separate front/rear brake hydraulic circuits. A decrease or loss of fluid pressure in either hydraulic circuit will cause the switch valve to shuttle forward or rearward in response to the pressure differential. Movement of the switch valve will push the switch plunger upward. This closes the switch internal contacts completing the electrical circuit to the warning lamp. The switch valve may remain in an actuated position until repair restores system pressures to normal levels. METERING VALVE The metering valve is used to balance brake action between the front disc and rear drum brakes. The valve holds-off the initial pressure to the front disc brakes until the rear brake shoes retracting springs are overcome. The valve is designed to maintain front brake fluid pressure at 241 - 517 kPa (35 - 75 psi) until the hold-off limit of 310 - 689 kPa (100 psi) is reached. At this point, the metering valve opens completely permitting full fluid apply pressure to the front disc brakes. This reduces front brake lining wear during low deceleration stops. PROPORTIONING VALVE The proportioning valve is used to balance front-rear brake action at high decelerations. The valve allows normal fluid flow during moderate braking. The valve only controls fluid flow during high decelerations brake stops, when a percentage of rear weight is transferred to the front wheels. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 4553 Brake Proportioning/Combination Valve: Testing and Inspection METERING VALVE Metering valve operation can be checked visually with the aid of a helper. Observe the metering valve stem while a helper applies and releases the brakes. If the valve is operating correctly, the stem will extend slightly when the brakes are applied and retract when the brakes are released. If the valve is faulty, replace the entire combination valve as an assembly. PRESSURE DIFFERENTIAL SWITCH 1. Have helper sit in drivers seat to apply brake pedal and observe red brake warning light. 2. Raise vehicle on hoist. 3. Connect bleed hose to a rear wheel cylinder and immerse hose end in container partially filled with brake fluid. 4. Have helper press and hold brake pedal to floor and observe warning light. a. If warning light illuminates, switch is operating correctly. b. If light fails to illuminate, check circuit fuse, bulb, and wiring. The parking brake switch can be used to aid in identifying whether or not the brake light bulb and fuse is functional. Repair or replace parts as necessary and test differential pressure switch operation again. 5. If warning light still does not illuminate, switch is faulty. Replace combination valve assembly, bleed brake system and verify proper switch and valve operation. PROPORTIONING VALVE Road test the vehicle and make several hard brake applications. If a premature rear wheel skid occurs this could be an indication the proportioning valve has malfunctioned. 1. Inspect and verify the rear brakes are clean, adjusted and operating properly. 2. Check the pressure in and out of the valve. The pressure should be equal up to the 250 psi. split point. 3. Above 250 psi. the output pressure should decrease on a 0.43 slope. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 4554 Brake Proportioning/Combination Valve: Service and Repair REMOVAL 1. Remove left turn signal housing. 2. Remove the extension panel under the left turn signal housing opening. Access Cover 3. Disconnect the horn connector and remove the access cover. 4. Remove the washer reservoir mounting screws. 5. Lift up the reservoir and disconnect the pump motor connector and pump hose. 6. Remove the reservoir from the engine compartment. Pressure Differential Switch 7. From the engine compartment disconnect the pressure differential switch wire from the combination valve. Then remove the brake lines from the switch side of the valve. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 4555 Combination Valve Brake Lines 8. Through the access cover opening, remove the other two brake lines from the valve. 9. Remove the valve mounting bolt and remove the valve through access cover opening. INSTALLATION 1. Position the valve on the mounting bracket. 2. Install the mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Install the brake lines and tighten to 13 Nm (115 inch lbs.). 4. Install the reservoir in the engine compartment. Connect the pump motor connector and pump hose. 5. Install the washer reservoir mounting screws. 6. Connect the horn connector and in-stall the access cover. 7. Install the extension panel. 8. Install left turn signal housing. 9. Fill and bleed brake system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > With Four Wheel Antilock Brakes Hydraulic Control Assembly - Antilock Brakes: Specifications With Four Wheel Antilock Brakes Bracket Nuts ........................................................................................................................................ ................................................ 12 Nm (102 inch lbs.) Mounting Bolts ................................................. ........................................................................................................................................ 15 Nm (11 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > With Four Wheel Antilock Brakes > Page 4560 Hydraulic Control Assembly - Antilock Brakes: Specifications With Rear Wheel Antilock Brakes Bracket Nuts ........................................................................................................................................ ................................................ 12 Nm (102 inch lbs.) Valve Bolt ........................................................ ......................................................................................................................................... 24 Nm (18 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > General Information Hydraulic Control Assembly - Antilock Brakes: Description and Operation General Information The controller-antilock brake module is used to monitor wheel speeds and modulates (control) hydraulic pressure in each brake channel. The modulated hydraulic pressure is used to prevent wheel lock up during braking. The CAB also provides a vehicle speed signal (VSS) to the powertrain control module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > General Information > Page 4563 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control Unit (HCU) Description The HCU on the EBC 2 has only a separate rear valve body. The HCU on the EBC 325 has two integral valve bodies for controlling the front and rear brakes. Within the HCU are solenoids, valves, check valves, and a reset switch necessary to apply and release brake pressure as required to avoid wheel lockup, keep the wheels rolling, and maintain optimum deceleration. The isolation valve is normally open, allowing unrestricted flow from the master cylinder to the wheels. When the CAB determines antilock intervention is required, the valve closes to isolate the master cylinder hydraulic circuit. Fluid is trapped in the circuit and then prevented from reaching the wheels. The dump valve is pulsed on and off by the CAB. This valve cycles only if the isolation valve is closed. When dump is on, it allows fluid to the low pressure accumulator for temporary storage. This causes the pressure to the wheel to decrease. When the valve is off, fluid is allowed to the wheel. The brake return check valve allows the HCU to drain faster after the ABS stop, when the brake is released. The Reset Switch is positioned in the HCU to monitor the master cylinder (input), rear brake (output) and accumulator pressure. During normal braking, pressure is equal for input and output and the switch remains open. During an Antilock stop the switch will close as the isolation valve is cycled and pressure becomes unequal between input and output. At the end of an ABS stop the isolation valve will open as master cylinder pressure and rear pressure equalize. The switch is used to monitor correct operation of the HCU and to set a diagnostic trouble code if incorrect pressure is detected. When the brakes are applied, fluid is forced from the master cylinder outlet ports to the HCU inlet ports. This pressure is transmitted through three normally open isolation valves inside the HCU, then through the outlet ports of the HCU to the wheels. If the CAB senses that a wheel is about to lock, based on wheel speed sensor data, it pulls the normally open isolation valve closed for that circuit. This prevents any more fluid from entering that circuit. The CAB continues to look at the sensor signal to determine if the wheel is still decelerating. If deceleration is still taking place, the normally closed dump valve for that circuit is opened. This dumps any pressure that is trapped between the normally open valve and the brake back into an accumulator. Once the affected circuit comes back up to speed, the CAB returns the valves to their normal condition allowing the affected brake to be reapplied. On the EBC 325 system, the pump and accumulators are used to provide rapid response during the reapply sequence and to minimize pedal feedback. With Four Wheel Antilock Brakes GENERAL INFORMATION CAB/HCU The Hydraulic Control Unit (HCU) consists of a valve body, pump, accumulator and motor. The pump, motor, and accumulator are combined into an assembly attached to the valve body. The accumulator store the extra fluid which had to be dumped from the brakes. This is done to prevent the wheels from locking up. The pump provides the fluid volume needed and is operated by a DC type motor. The motor is controlled by the Controller Antilock Brake (CAB). The valve body contains the solenoid valves. The valves modulate brake pressure during antilock braking and are controlled by the CAB. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > General Information > Page 4564 The HCU provides three channel pressure control to the front and rear brakes. One channel controls the rear wheel brakes in tandem. The two remaining channels control the front wheel brakes individually. During antilock braking, the solenoid valves are opened and closed as needed. The valves are not static. They are cycled rapidly and continuously to modulate pressure and control wheel slip and deceleration. During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder and power booster operate the same as a vehicle without an ABS brake system. During antilock braking, solenoid valve pressure modulation occurs in three stages, pressure decrease, pressure hold, and pressure increase. The valves are all contained in the valve body portion of the HCU. Pressure Decrease The inlet valve is closed and the outlet valve is opened during the pressure decrease cycle. A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the CAB closes the inlet to prevent the driver from further increasing the brake pressure and locking the brakes. The CAB then opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent wheel lock. Once the period of high wheel slip has ended, the CAB closes the outlet valve and begins a pressure increase or hold cycle as needed. Pressure Hold Both solenoid valves are closed in the pressure hold cycle. Fluid apply pressure in the control channel is maintained at a constant rate. The CAB maintains the hold cycle until sensor inputs indicate a pressure change is necessary. Pressure Increase The inlet valve is open and the outlet valve is closed during the pressure increase cycle. The pressure increase cycle is used to counteract unequal wheel speeds. This cycle controls re-application of fluid apply pressure due to changing road surfaces or wheel speed. With Rear Wheel Antilock Brakes If the Controller Antilock Brake (CAB) senses that rear wheel speed deceleration is excessive, it will energize a isolation solenoid by providing battery voltage to the solenoid. This prevents a further increase of driver induced brake pressure to the rear wheels. If this initial action is not enough to prevent rear wheel lock-up, the CAB will momentarily energize a dump solenoid (the CAB energizes the dump solenoid by providing battery voltage to the solenoid). This opens the dump valve to vent a small amount of isolated rear brake pressure to an accumulator. The action of fluid moving to the accumulator reduces the isolated brake pressure at the wheel cylinders. The dump (pressure venting) cycle is limited to very short time periods (milliseconds). The CAB will pulse the dump valve until rear wheel deceleration matches the vehicle deceleration rate or the desired slip rate programmed into the CAB. The system will switch to normal braking once wheel locking tendencies are no longer present. A predetermined maximum number of consecutive dump cycles can be performed during any one antilock stop. If excessive dump cycles occur, a DTC will be set and stored in the CAB memory. If during an antilock stop, the driver releases the brake pedal, the reset switch contacts will open. This signal to the CAB is an indication that pressure has equalized across the RWAL valve. The CAB will then reset the dump cycle counter in anticipation of the next antilock stop. Additionally, any fluid stored in the accumulator will force its way past the dump valve, back into the hydraulic circuit and return to the master cylinder. A fuse internal to the CAB, provides a fail-safe device which prevents unwanted control over the isolation and dump solenoids. The fuse is in series with the isolation and dump solenoids output circuits. If the internal fuse is open, the CAB cannot provide voltage to energize either solenoid and antilock stops are prevented. If the fuse is open, the braking system will operate normally but without antilock control over rear brake pressure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Front Antilock Valve Replacement NOTE: If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new Controller Antilock Brake (CAB). REMOVAL 1. Remove left turn signal housing. 2. Remove the extension panel under the left turn signal housing opening. Access Cover 3. Disconnect the horn connector and remove the access cover. 4. Remove the washer reservoir mounting screws. 5. Lift up the reservoir and disconnect the pump motor connector and pump hose. 6. Remove the reservoir from the engine compartment. 7. Disconnect battery cables and remove the battery. 8. Remove the power distribution center. 9. Remove the battery and power distribution center mount. Harness Connector Locks 10. Push the harness connectors locks to release the locks, then remove the connectors from the CAB. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement > Page 4567 HCU Brake Lines 11. Disconnect brake lines from Hydraulic Control Unit (HCU). 12. Remove the front mounting bolt through access opening. 13. Remove the rear mounting bolt from the engine compartment. 14. Tilt the assembly upward were the brake lines attach and remove the assembly from the mounting bracket. INSTALLATION 1. Install the assembly into the mounting bracket. 2. Install mounting bolts and tighten to 15 Nm (11 ft. lbs.). 3. Install the brake lines to HCU and tighten to 13 Nm (115 inch lbs.). 4. Connect the CAB harness connectors and lock in place. 5. Install the reservoir in the engine compartment. Connect the pump motor connector and pump hose. 6. Install the washer reservoir mounting screws. 7. Install the battery and power distribution center mount. 8. Install the power distribution center. 9. Install the battery and battery cables. 10. Connect the horn connector and install the access cover. 11. Install the extension panel. 12. Install left turn signal housing. 13. Bleed the brake system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement > Page 4568 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Rear Antilock Valve Replacement REMOVAL 1. Remove left turn signal housing. 2. Remove the extension panel under the left turn signal housing opening. Access Cover 3. Disconnect the horn connector and remove the access cover. 4. Remove one brake line from the rear antilock valve through the access cover opening. 5. From the engine compartment, disconnect antilock valve harness connector from the controller. 6. Remove the other brake line and mounting bolt from the antilock valve. 7. Remove rear antilock valve. INSTALLATION 1. Position rear antilock valve on the valve bracket. 2. Install the mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Install the brake lines and tighten to 15 Nm (130 inch lbs.). 4. Connect wiring harness wires to the controller. 5. Connect the horn connector and install the access cover. 6. Install the extension panel. 7. Install left turn signal housing. 8. Fill and bleed brake system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > With Antilock Brakes Brake Master Cylinder: Specifications With Antilock Brakes Mounting Nuts ..................................................................................................................................... ..................................................... 23 Nm (17 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > With Antilock Brakes > Page 4573 Brake Master Cylinder: Specifications Without Antilock Brakes Mounting Nuts ..................................................................................................................................... ..................................................... 23 Nm (17 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4574 Brake Master Cylinder: Description and Operation A two-piece master cylinder is used on all models. The cylinder body containing the primary and secondary pistons is made of aluminum. The removable fluid reservoir is made of nylon reinforced with glass fiber. The reservoir is the only serviceable component. The fluid compartments of the nylon reservoir are interconnected to permit fluid level equalization. However, the equalization feature does not affect circuit separation in the event of a front or rear brake malfunction. The reservoir compartments will retain enough fluid to operate the functioning hydraulic circuit. Care must be exercised when removing/installing the master cylinder connecting lines. The threads in the cylinder fluid ports can be damaged if care is not exercised. Start all brake line fittings by hand to avoid cross threading. The cylinder reservoir can be replaced when necessary. However, the aluminum body section of the master cylinder is not a repairable component. NOTE: If diagnosis indicates that an internal malfunction has occurred, the aluminum body section must be replaced as an assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4575 Brake Master Cylinder: Testing and Inspection 1. Start engine and check booster vacuum hose connections. A hissing noise indicates vacuum leak. Correct any vacuum leak before proceeding. 2. Stop engine and shift transmission into Neutral. 3. Pump brake pedal until all vacuum reserve in booster is depleted. 4. Press and hold brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master cylinder is faulty (internal leakage). 5. Start engine and note pedal action it should fall away slightly under light foot pressure then hold firm. If no pedal action is discernible, power booster, vacuum supply, or vacuum check valve is faulty. Proceed to the POWER BOOSTER VACUUM TEST. 6. If the POWER BOOSTER VACUUM TEST passes, rebuild booster vacuum reserve as follows: Release brake pedal. Increase engine speed to 1500 rpm, close the throttle and immediately stop turn off ignition to stop engine. 7. Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more vacuum assisted pedal applications. If vacuum assist is not provided, booster is faulty. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bleeding GENERAL INFORMATION A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. BLEEDING PROCEDURE 1. Mount master cylinder in vise. Master Cylinder Bleeding - Typical 2. Attach bleed tubes to cylinder outlet ports. Then position each tube end into the reservoir. 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4578 Brake Master Cylinder: Service and Repair Master Cylinder Replacement REMOVAL Master Cylinder 1. Remove brake lines from master cylinder. 2. Remove master cylinder mounting nuts. 3. Remove master cylinder from mounting studs. INSTALLATION NOTE: If master cylinder is replaced, bench bleed before installation. 1. Position master cylinder on mounting studs. 2. Install mounting nuts and tighten to 23 Nm (17 ft. lbs.). 3. Install brake lines and tighten to 16 Nm (145 inch lbs.). 4. Bleed brake system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4579 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement REMOVAL 1. Remove the master cylinder. 2. Remove reservoir cap and empty fluid into drain container. Reservoir Retaining Pins 3. Remove pins that retain reservoir to master cylinder. Use hammer and pin punch to remove pins. 4. Clamp cylinder body in vise with brass protective jaws. Loosening Reservoir 5. Loosen reservoir from grommets with pry tool. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4580 6. Remove reservoir by rocking it to one side and pulling free of grommets. 7. Remove old grommets from cylinder body. INSTALLATION CAUTION: Install the grommets using fingers only. Installation with tools may cut or tear the grommets. 1. Lubricate new grommets with clean brake fluid and Install new grommets in cylinder body. Use finger pressure to install and seat grommets. 2. Position the reservoir into the grommets. Then rock reservoir back and forth while pressing downward to seat it in grommets. 3. Install the reservoir retaining pins into the cylinder body. 4. Bleed master cylinder on bench before installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Bolts/Nuts 15 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 4584 Wheel Cylinder Components-Typical Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation REMOVAL 1. Remove wheel and tire assembly. 2. Remove brake drum. 3. Disconnect wheel cylinder brake line. 4. Remove brake shoe return springs and move shoes out of engagement with cylinder push rods. 5. Remove cylinder attaching bolts and remove cylinder from support plate. INSTALLATION 1. Apply bead of silicone sealer around cylinder mounting surface of support plate. 2. Install cylinder mounting bolts and tighten to 20 Nm (15 ft. lbs.). 3. Connect brake line to cylinder. 4. Install brake shoe return spring. 5. Install brake drum. 6. Install wheel and tire assembly. 7. Bleed brake system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4587 Wheel Cylinder: Service and Repair Cleaning and Inspection CLEANING Clean the cylinder and pistons with clean brake fluid or brake cleaner only. Do not use any other cleaning agents. Dry the cylinder and pistons with compressed air. Do not use rags or shop towels to dry the cylinder components. Lint from cloth material will adhere to the cylinder bores and pistons. INSPECTION Inspect the cylinder bore. Light discoloration and dark stains in the bore are normal and will not impair cylinder operation. The cylinder bore can be lightly polished but only with crocus cloth. Replace the cylinder if the bore is scored, pitted or heavily corroded. Honing the bore to restore the surface is not recommended. Inspect the cylinder pistons. The piston surfaces should be smooth and free of scratches, scoring and corrosion. Replace the pistons if worn, scored, or corroded. Do attempt to restore the surface by sanding or polishing. Discard the old piston cups and the spring and expander. These parts are not reusable. The original dust boots may be reused but only if they are in good condition. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4588 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul DISASSEMBLY 1. Remove push rods and boots. 2. Press pistons, cups and spring and expander out of cylinder bore. 3. Remove bleed screw. ASSEMBLY 1. Lubricate wheel cylinder bore, pistons, piston cups and spring and expander with clean brake fluid. 2. Install first piston in cylinder bore. Then install first cup in bore and against piston. Be sure lip of piston cup is facing inward (toward spring and expander) and flat side is against piston. 3. Install spring and expander followed by remaining piston cup and piston. 4. Install boots on each end of cylinder and insert push rods in boots. 5. Install cylinder bleed screw. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement Parking Brake Cable: Service and Repair Front Cable Replacement NOTE: To compress tabs on cable housing retainers use a 1/2 inch boxed end wrench. REPLACEMENT 1. Raise and support vehicle. 2. Loosen adjusting nut to create slack in front cable. 3. Remove the front cable from the cable connector. 4. Compress cable housing retainer tabs at underbody bracket and remove the cable from the bracket. 5. Lower vehicle. 6. Push ball end of cable out of pedal clevis with small screwdriver. Parking Brake Pedal 7. Compress cable housing retainer tabs at the pedal bracket and remove the cable. 8. Remove the left cowl trim and sill plate. 9. Pull up the carpet and remove the cable from the body clip. 10. Pull up on the cable and remove the cable with the body grommet. INSTALLATION 1. From inside vehicle, insert cable housing retainer into hole in pedal assembly. 2. Seat cable retainer in pedal assembly. 3. Engage cable ball end in clevis on pedal assembly. 4. Route cable along the top of the wheel well and clip in place. 5. Route cable through the floorpan and install body grommet. 6. Place carpet down and install the left cowl trim and sill plate. 7. Raise and support vehicle. 8. Route cable through the underbody bracket and seat cable housing retainer in bracket. 9. Connect cable to the cable connector. 10. Perform park brake adjustment procedure. 11. Lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 4594 Parking Brake Cable: Service and Repair Rear Cable Replacement NOTE: To compress tabs on cable housing retainers use a 1/2 inch boxed end wrench. REMOVAL 1. Release parking brakes. 2. Raise and support vehicle. 3. Loosen cable adjuster nut. Rear Park Brake Cables 4. Remove the rear cables from the cable tensioner bracket. 5. Remove the right rear cable retainer clip from the frame bracket. Then pull the cable through the bracket. 6. Compress tabs on them left cable housing retainer. Then pull the cable through the frame bracket. 7. Pull the right rear cable through the brake hose bracket and remove the cable retainers from the axle. 8. Remove rear wheels and brake drums. 9. Disconnect each cable from the park brake lever. 10. Remove cable guide spring. 11. Compress cable tabs on each cable housing retainer at the brake support plate. 12. Remove the cables from the brake support plates. INSTALLATION 1. Install cable guide spring. 2. Install the brake drums. 3. Push each cable housing through the brake support plate hole until the cable housing retainer tabs lock into place. NOTE: Pull on the cable housing to ensure it is locked into place. 4. Pull back on the cable. Then push the cable in to engage the cable in the park brake lever. NOTE: Pull on the cable end to ensure it is attached to the park brake lever. 5. Install the right cable retainers on the axle. The push the right cable through the hole in the brake hose bracket. 6. Push both cables through the frame bracket. Push the left cable until the cable housing retainer tabs lock into place. Install the retainer clip on the right cable. NOTE: The right cable must be installed in the top hole of the bracket and left cable in the bottom hole. 7. Install the cables onto the cable tensioner bracket and install the cables into the cable connectors. 8. Install the wheel and tire assemblies. 9. Perform park brake adjustment procedure. 10. Remove supports and lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair Parking Brake Pedal: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Loosen adjuster nut at the tensioner. 3. Remove front cable from the cable connector. 4. Lower vehicle. 5. Push ball end of cable out of pedal clevis on the pedal assembly with small screwdriver. 6. Compress cable housing retainer at pedal bracket and remove cable. Compress cable housing retainer with 1/2 boxed end wrench. 7. Disconnect the park brake lamp switch. 8. Remove the park brake release from the knee blocker. Parking Brake Pedal 9. Remove mounting bolts. 10. Remove assembly. INSTALLATION 1. Install park brake pedal assembly and install mounting bolts. 2. Tighten mounting bolts to 54 Nm (40 ft. lbs.). 3. Seat cable housing retainer into pedal bracket. 4. Install ball end of cable into clevis on the pedal assembly. 5. Raise vehicle and install front cable into the cable connector. 6. Perform park brake adjustment procedure. 7. Lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications DIMENSIONS: Type ..................................................................................................................................................... ...................................... 250 mm Dual Diaphragm TIGHTENING TORQUES: Mounting Nuts ..................................................................................................................................... ................................................. 18 Nm (13 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4602 Vacuum Brake Booster: Description and Operation Power assisted brakes are standard on all models. A dual diaphragm, vacuum operated power brake booster is used to provide assist. The booster unit consists of a single housing divided into separate chambers by two internal diaphragms. The outer edge of the diaphragm is secured to the housing. The booster push rod, which connects the booster to the brake pedal and master cylinder, is attached to the center of the diaphragm. A check valve is used in the booster inlet and is connected to the engine intake manifold. Power assist is generated utilizing a combination of vacuum and atmospheric pressure to boost brake assist. NOTE: The power brake booster is not a repairable component. The booster must be replaced as an assembly if diagnosis indicates a malfunction has occurred. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Operational Test Vacuum Brake Booster: Testing and Inspection Operational Test 1. Start engine and check booster vacuum hose connections. A hissing noise indicates vacuum leak. Correct any vacuum leak before proceeding. 2. Stop engine and shift transmission into Neutral. 3. Pump brake pedal until all vacuum reserve in booster is depleted. 4. Press and hold brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master cylinder is faulty (internal leakage). 5. Start engine and note pedal action it should fall away slightly under light foot pressure then hold firm. If no pedal action is discernible, power booster, vacuum supply, or vacuum check valve is faulty. Proceed to the POWER BOOSTER VACUUM TEST. 6. If the POWER BOOSTER VACUUM TEST passes, rebuild booster vacuum reserve as follows: Release brake pedal. Increase engine speed to 1500 rpm, close the throttle and immediately stop turn off ignition to stop engine. 7. Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more vacuum assisted pedal applications. If vacuum assist is not provided, booster is faulty. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Operational Test > Page 4605 Vacuum Brake Booster: Testing and Inspection Vacuum Test Typical Booster Vacuum Test Connections 1. Connect vacuum gauge to booster check valve with short length of hose and T-fitting. 2. Start and run engine at curb idle speed for one minute. 3. Observe the vacuum supply. If vacuum supply is not adequate, repair vacuum supply. 4. Clamp hose shut between vacuum source and check valve. 5. Stop engine and observe vacuum gauge. 6. If vacuum drops more than one inch HG (33 millibars) within 15 seconds, booster diaphragm or check valve is faulty. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 4606 Vacuum Brake Booster: Service and Repair REMOVAL 1. Remove vacuum hoses from booster check valve. 2. Remove the master cylinder. 3. Inside vehicle, remove steering column lower cover and knee blocker for access to brake pedal. Booster Push Rod 4. Remove clip that attaches booster push rod to brake pedal pin. Power Brake Booster 5. Remove booster mounting nuts. 6. Remove booster and booster dash seal. INSTALLATION 1. Position seal on booster. 2. Mount booster on dash panel. 3. Slide booster push rod onto brake pedal pin. Then secure push rod with retaining clip. 4. Install booster mounting nuts and tighten to 18 Nm (13 ft. lbs.). 5. Install knee blocker and lower column cover. 6. Install the master cylinder. 7. Install booster vacuum hose. 8. Fill and bleed brake system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Testing and Inspection Vacuum Brake Booster Check Valve: Testing and Inspection 1. Disconnect vacuum hose from check valve. 2. Remove check valve and valve seal from booster. 3. Use a hand operated vacuum pump for test. Vacuum Check Valve And Seal 4. Apply 15 - 20 inches vacuum at large end of check valve. 5. Vacuum should hold steady. If gauge on pump indicates vacuum loss, check valve is faulty and should be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion Technical Service Bulletin # D20 Date: 040901 Recall - ABS Wiring Corrosion September 2004 Dealer Service Instructions for: Safety Recall D20 - ABS Wiring Corrosion Models 1998-2003 (AB) Dodge Ram Van/Wagon NOTE: This recall applies only to the above vehicles equipped with a 4-wheel Anti-lock Brake System (ABS) (sales code BGK). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject Electrolyte (battery acid) from aftermarket batteries may leak onto an Antilock Brake System (ABS) wiring connector on about 43,000 of the above vehicles. This may cause the wiring to corrode and short circuit, which can result in an underhood fire. Repair All vehicles must have a revised battery tray installed that will protect the ABS control module wiring harness connector from future electrolyte leakage. A cowl seal extension must also be installed on all vehicles to redirect any water draining from the windshield away from the battery. The ABS control module wiring harness and connector must be inspected for electrolyte damage and repaired if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4619 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4620 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4621 Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Install Cowl Seal Extension 1. Open the hood. 2. Using Mopar glass cleaner and a shop cloth, clean the plastic cowl panel where the cowl seal ends on the driver's side of the vehicle (Figure 1). 3. Test fit the cowl seal extension. Cut the cowl seal extension length so that the seal stops at the end of the plastic cowl panel (Figure 1). 4. Insert the cowl seal connector halfway into the cowl seal extension (Figure 2). 5. Remove the protective plastic covering from the glue strip on the cowl seal extension. 6. Install the cowl seal extension connector into the original cowl seal end and firmly press the seal against the plastic cowl panel (Figure 2). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4622 7. Continue with Section B. Inspect ABS Control Module Wiring Harness Connector. B. Inspect ABS Control Module Wiring Harness Connector 1. Turn the ignition switch to the "Off" position. Be certain that all electrical accessories are turned off. 2. Loosen the battery negative cable clamp pinch-bolt hex nut. 3. Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 4. Loosen the battery positive cable terminal clamp pinch-bolt hex nut. 5. Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 6. Remove the two nuts with washers that secure the battery hold down strap to the threaded end of the J-bolt and the long stud (Figure 4). 7. Remove the battery hold down strap from the top of the battery (Figure 4). 8. Remove the J-bolt from the holes in the battery tray support on the inboard side of the battery tray (Figure 4). 9. Carefully remove the battery from the battery tray. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4623 WARNING: Wear a suitable pair of rubber gloves when removing the battery. Safety glasses should also be worn. 10. Remove the three screws that secure the bottom of the battery tray to the battery tray support (Figure 5). 11. Remove the two screws that secure the outboard side of the battery tray to the left cowl side panel (Figure 5). 12. Lift the battery tray slightly and disconnect the battery temperature sensor electrical connector. 13. Remove the battery tray and the drain tube from the vehicle as an assembly (Figure 5). 14. In the area below the battery location, inspect the front (large) wiring harness connector on the ABS control module for acid damage, by spraying the connector and surrounding area with the provided Electrolyte Detection and Neutralizing Spray (Figure 6). > If the spray remains an orange color, there is no electrolyte (battery acid) on the ABS control module wiring harness connector. Continue with Section E - Battery Tray Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4624 > If the spray turns a purple color, continue with Step 15 of this procedure. 15. Disconnect the large ABS control module wiring harness connector from the ABS control module by first sliding the red lock tab forward. Then push down on the black release tab while pulling the connector from the module (Figure 7). 16. Inspect the large ABS control module wiring harness connector: a. If a heat damaged (melted) connector is found, replace the wiring harness connector. Continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no heat damage is found continue with inspection Step b. b. Inspect the wire side and the terminal side of the large ABS control module wiring harness connector for green colored corrosion. If green colored corrosion is found in one or more of the connector cavities continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no green colored corrosion is found, continue with inspection Step c. c. Looking into the terminal side of the large ABS control module wiring harness connector, inspect the metal terminals for a dull finish or discoloration. If a dull finish or discoloration is found, continue with Section C - ABS Control Module Wiring Harness Connector Replacement because the original connector housing wire weather seals have been damaged. If no dull or discolored terminals are found continue with Section E - Battery Tray Installation. C. ABS Control Module Wiring Harness Connector Replacement NOTE: Only ABS control module wiring harness connectors with heat damage (melted), green wire terminals or dull/discolored terminals, as determined by the inspection in Section B, require replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4625 1. Remove the secondary terminal lock from the original ABS control module wiring harness connector housing (Figure 8). 2. Some models may have two empty wire cavities in the ABS control module wiring harness connector housing. Insert the gray wire cavity plugs supplied with the repair kit into the correct cavities of the new ABS control module wiring harness connector. 3. The ABS control module wiring harness connector terminals that do not have heat damage, green corrosion or are only dull or discolored can be transferred to the new connector using the following process: a. From the terminal side of the connector, insert a small pick into the connector next to the terminal and push on the terminal release arm while pulling on the wire. CAUTION: Remove only one wire from the original connector at a time and note which connector cavity the wire is to be transfer into. b. Using the electrolyte detection and neutralizing spray, lightly spray the removed wire until the spray remains an orange color. This may require two or three applications. c. Using compressed air, carefully dry the terminal and wire. d. Insert the terminal into the proper connector cavity of the new connector housing. e. Repeat Steps a. through d. on all wires that need to be transferred to the new connector housing. 4. The ABS control module wiring harness connector terminals with heat damage and/or green corrosion must be replaced using the following process: a. Cut off the wire one inch back from the original ABS connector. b. Remove one-half (1/2) inch (13 mm) of insulation from the wire on the harness that needs to be spliced. c. Cut the replacement wire supplied in the connector repair kit to the required length. Then remove one-half (1/2) inch (13 mm) of insulation from the wire. d. Place a piece of sealant lined heat shrink tubing on one side of the wire. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4626 e. Place the strands of wire overlapping each other inside of the brass splice band (Figure 9). f. Using crimp tool (Mopar P/N 05019912AA), crimp the brass splice band and wires together (Figure 10). g. Solder the connection together using rosin core type solder. DO NOT use acid core solder. CAUTION: All splices must be properly soldered. Failure to properly solder these wiring connectors can cause the ABS to become inoperative in the future. h. Center the shrink tubing over the splice joint. Using a heat gun, heat the surface of the shrink tubing until the shrink tubing is tightly sealed and sealant comes out of both ends of the shrink tubing (Figure 11). 5. After all of the terminals have been transferred or replaced, install the blue secondary terminal lock into the ABS control module wiring harness connector (Figure 8). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4627 6. Using a small mirror (Snap-on GA295 or equivalent), inspect the ABS control module connector pins for green corrosion and the connector housing for heat damage (Figure 12). > ABS control module connectors found with green corroded pins continue with Section D - ABS Control Module Replacement. > ABS control module connector housings found with heat damage continue with Section D - ABS Control Module Replacement. > ABS control module connectors found without heat damage or green corroded pins continue with Section E - Battery Tray Installation. D. ABS Control Module Replacement NOTE: Only ABS control modules with a heat damaged (melted) connector or green corroded connector pins, as determined by the inspection in Section B and C, require replacement. Very few vehicles are expected to require ABS control module replacement. 1. Disconnect the small ABS control module wiring connector from the ABS control module (Figure 13). 2. Remove the four mounting screws on the ABS control module (Figure 13). 3. Lift the module from the ABS hydraulic control unit and disconnect the solenoid connector located on the bottom side of the ABS control module. 4. Remove the ABS control module from the vehicle and discard. 5. Using a clean shop towel, clean the ABS control module mounting surface on the ABS hydraulic control unit. 6. Connect the solenoid connector to the new ABS control module and then place the module into position on the ABS hydraulic control unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4628 7. Install the four ABS control module mounting screws. Tighten the screws to 39 in. lbs (4.4 N.m). 8. Continue with Section E - Battery Tray Installation. E. Battery Tray Installation 1. If disconnected, spray the ABS control module connector and the ABS control module wiring harness connector with Electrolyte Detection and Neutralizing spray to ensure that all traces of acid have been neutralized. NOTE: When the spray remains an orange color, any remaining battery acid has been neutralized. 2. Using compressed air, carefully blow out the connector until completely dry. 3. If previously disconnected, connect the large and/or small wiring harness connectors to the ABS control module. 4. Transfer the battery temperature sensor from the old battery tray to the new battery tray (Figure 14). Then discard the old battery tray. 5. Place a small bead of RTV silicone rubber adhesive (P/N 04883971) onto the base of the new drain tube grommet. 6. Snap the new drain tube into position on the new battery tray (Figure 14). 7. While installing the new battery tray into position, route the drain tube through the original hole in the fender panel (Figure 15) and connect the battery temperature sensor electrical connector. 8. Install the battery tray mounting bolts. Tighten the bolts to 95 in. lbs. (10.7 N.m). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4629 9. Install the battery onto the new battery tray. 10. Install the "J" hook and battery hold down bracket. 11. Install the battery hold down retaining nuts. Tighten the nuts to 24 in. lbs. (2.7 N.m). 12. Connect the positive battery cable to the positive battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 13. Connect the negative battery cable to the negative battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 14. From inside the left wheel well housing, secure the battery tray drain tube to the frame rail bracket with the provided plastic tie strap (Figure 16). 15. If the ABS control module was replaced, connect the DRB III scan tool to the vehicle and program the rear axle ratio and tire size into the new control module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4630 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA04V185000 > Apr > 04 > Recall 04V185000: ABS Control Module Corrosion Electronic Brake Control Module: Recalls Recall 04V185000: ABS Control Module Corrosion DEFECT: On some van and wagon model vehicles equipped with 4-wheel antilock brake systems (ABS), aftermarket batteries may leak electrolyte onto the ABS control module connector, which can compromise the sealing integrity of the connector. This may allow development of a short circuit in the connector, which could eventually lead to a fire. REMEDY: Dealers will inspect the ABS control module connector for electrolyte damage and replace the connector as necessary. The manufacturer has not yet provided an owner notification for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-002-02 > Jan > 02 > Rear Axle - Vehicle Speed Is Inaccurate Electronic Brake Control Module: Customer Interest Rear Axle - Vehicle Speed Is Inaccurate NUMBER: 18-002-02 GROUP: Vehicle Performance DATE: January 21, 2002 THE MDS2(R) MUST BE OPERATING WITH CIS CD2094 OR HIGHER, AVAILABLE OCTOBER 29, 2001. THE DRBIII(R) MUST BE AT LEVEL 52.5 OR LATER. SUBJECT: Pinion Factor Recalibration MODELS: 1998-2002 AB Ram Van NOTE: THIS BULLETIN APPLIES TO ALL 1998 - 2002 (AB) RAM VANS EQUIPPED WITH THE 9.25 REAR AXLE. DISCUSSION: Owners of 1998 - 2002 (AB) Ram Vans equipped with the 9.25 rear axle may complain that vehicle speed is inaccurate. It may be that past service on the rear axle has caused the calibration to change. Accurate calibration can be restored by reprogramming the applicable module, (ABS) Antilock Brake System or (RWAL) Rear Wheel Antilock, using the DRBI III(R). NOTE: THE DRBIII(R) MUST BE AT LEVEL 52.5 OR HIGHER AND THE MDSII(R) AT CD 2094 OR HIGHER TO PERFORM THE REPROGRAMMING. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion Technical Service Bulletin # D20 Date: 040901 Recall - ABS Wiring Corrosion September 2004 Dealer Service Instructions for: Safety Recall D20 - ABS Wiring Corrosion Models 1998-2003 (AB) Dodge Ram Van/Wagon NOTE: This recall applies only to the above vehicles equipped with a 4-wheel Anti-lock Brake System (ABS) (sales code BGK). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject Electrolyte (battery acid) from aftermarket batteries may leak onto an Antilock Brake System (ABS) wiring connector on about 43,000 of the above vehicles. This may cause the wiring to corrode and short circuit, which can result in an underhood fire. Repair All vehicles must have a revised battery tray installed that will protect the ABS control module wiring harness connector from future electrolyte leakage. A cowl seal extension must also be installed on all vehicles to redirect any water draining from the windshield away from the battery. The ABS control module wiring harness and connector must be inspected for electrolyte damage and repaired if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4645 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4646 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4647 Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Install Cowl Seal Extension 1. Open the hood. 2. Using Mopar glass cleaner and a shop cloth, clean the plastic cowl panel where the cowl seal ends on the driver's side of the vehicle (Figure 1). 3. Test fit the cowl seal extension. Cut the cowl seal extension length so that the seal stops at the end of the plastic cowl panel (Figure 1). 4. Insert the cowl seal connector halfway into the cowl seal extension (Figure 2). 5. Remove the protective plastic covering from the glue strip on the cowl seal extension. 6. Install the cowl seal extension connector into the original cowl seal end and firmly press the seal against the plastic cowl panel (Figure 2). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4648 7. Continue with Section B. Inspect ABS Control Module Wiring Harness Connector. B. Inspect ABS Control Module Wiring Harness Connector 1. Turn the ignition switch to the "Off" position. Be certain that all electrical accessories are turned off. 2. Loosen the battery negative cable clamp pinch-bolt hex nut. 3. Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 4. Loosen the battery positive cable terminal clamp pinch-bolt hex nut. 5. Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 6. Remove the two nuts with washers that secure the battery hold down strap to the threaded end of the J-bolt and the long stud (Figure 4). 7. Remove the battery hold down strap from the top of the battery (Figure 4). 8. Remove the J-bolt from the holes in the battery tray support on the inboard side of the battery tray (Figure 4). 9. Carefully remove the battery from the battery tray. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4649 WARNING: Wear a suitable pair of rubber gloves when removing the battery. Safety glasses should also be worn. 10. Remove the three screws that secure the bottom of the battery tray to the battery tray support (Figure 5). 11. Remove the two screws that secure the outboard side of the battery tray to the left cowl side panel (Figure 5). 12. Lift the battery tray slightly and disconnect the battery temperature sensor electrical connector. 13. Remove the battery tray and the drain tube from the vehicle as an assembly (Figure 5). 14. In the area below the battery location, inspect the front (large) wiring harness connector on the ABS control module for acid damage, by spraying the connector and surrounding area with the provided Electrolyte Detection and Neutralizing Spray (Figure 6). > If the spray remains an orange color, there is no electrolyte (battery acid) on the ABS control module wiring harness connector. Continue with Section E - Battery Tray Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4650 > If the spray turns a purple color, continue with Step 15 of this procedure. 15. Disconnect the large ABS control module wiring harness connector from the ABS control module by first sliding the red lock tab forward. Then push down on the black release tab while pulling the connector from the module (Figure 7). 16. Inspect the large ABS control module wiring harness connector: a. If a heat damaged (melted) connector is found, replace the wiring harness connector. Continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no heat damage is found continue with inspection Step b. b. Inspect the wire side and the terminal side of the large ABS control module wiring harness connector for green colored corrosion. If green colored corrosion is found in one or more of the connector cavities continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no green colored corrosion is found, continue with inspection Step c. c. Looking into the terminal side of the large ABS control module wiring harness connector, inspect the metal terminals for a dull finish or discoloration. If a dull finish or discoloration is found, continue with Section C - ABS Control Module Wiring Harness Connector Replacement because the original connector housing wire weather seals have been damaged. If no dull or discolored terminals are found continue with Section E - Battery Tray Installation. C. ABS Control Module Wiring Harness Connector Replacement NOTE: Only ABS control module wiring harness connectors with heat damage (melted), green wire terminals or dull/discolored terminals, as determined by the inspection in Section B, require replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4651 1. Remove the secondary terminal lock from the original ABS control module wiring harness connector housing (Figure 8). 2. Some models may have two empty wire cavities in the ABS control module wiring harness connector housing. Insert the gray wire cavity plugs supplied with the repair kit into the correct cavities of the new ABS control module wiring harness connector. 3. The ABS control module wiring harness connector terminals that do not have heat damage, green corrosion or are only dull or discolored can be transferred to the new connector using the following process: a. From the terminal side of the connector, insert a small pick into the connector next to the terminal and push on the terminal release arm while pulling on the wire. CAUTION: Remove only one wire from the original connector at a time and note which connector cavity the wire is to be transfer into. b. Using the electrolyte detection and neutralizing spray, lightly spray the removed wire until the spray remains an orange color. This may require two or three applications. c. Using compressed air, carefully dry the terminal and wire. d. Insert the terminal into the proper connector cavity of the new connector housing. e. Repeat Steps a. through d. on all wires that need to be transferred to the new connector housing. 4. The ABS control module wiring harness connector terminals with heat damage and/or green corrosion must be replaced using the following process: a. Cut off the wire one inch back from the original ABS connector. b. Remove one-half (1/2) inch (13 mm) of insulation from the wire on the harness that needs to be spliced. c. Cut the replacement wire supplied in the connector repair kit to the required length. Then remove one-half (1/2) inch (13 mm) of insulation from the wire. d. Place a piece of sealant lined heat shrink tubing on one side of the wire. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4652 e. Place the strands of wire overlapping each other inside of the brass splice band (Figure 9). f. Using crimp tool (Mopar P/N 05019912AA), crimp the brass splice band and wires together (Figure 10). g. Solder the connection together using rosin core type solder. DO NOT use acid core solder. CAUTION: All splices must be properly soldered. Failure to properly solder these wiring connectors can cause the ABS to become inoperative in the future. h. Center the shrink tubing over the splice joint. Using a heat gun, heat the surface of the shrink tubing until the shrink tubing is tightly sealed and sealant comes out of both ends of the shrink tubing (Figure 11). 5. After all of the terminals have been transferred or replaced, install the blue secondary terminal lock into the ABS control module wiring harness connector (Figure 8). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4653 6. Using a small mirror (Snap-on GA295 or equivalent), inspect the ABS control module connector pins for green corrosion and the connector housing for heat damage (Figure 12). > ABS control module connectors found with green corroded pins continue with Section D - ABS Control Module Replacement. > ABS control module connector housings found with heat damage continue with Section D - ABS Control Module Replacement. > ABS control module connectors found without heat damage or green corroded pins continue with Section E - Battery Tray Installation. D. ABS Control Module Replacement NOTE: Only ABS control modules with a heat damaged (melted) connector or green corroded connector pins, as determined by the inspection in Section B and C, require replacement. Very few vehicles are expected to require ABS control module replacement. 1. Disconnect the small ABS control module wiring connector from the ABS control module (Figure 13). 2. Remove the four mounting screws on the ABS control module (Figure 13). 3. Lift the module from the ABS hydraulic control unit and disconnect the solenoid connector located on the bottom side of the ABS control module. 4. Remove the ABS control module from the vehicle and discard. 5. Using a clean shop towel, clean the ABS control module mounting surface on the ABS hydraulic control unit. 6. Connect the solenoid connector to the new ABS control module and then place the module into position on the ABS hydraulic control unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4654 7. Install the four ABS control module mounting screws. Tighten the screws to 39 in. lbs (4.4 N.m). 8. Continue with Section E - Battery Tray Installation. E. Battery Tray Installation 1. If disconnected, spray the ABS control module connector and the ABS control module wiring harness connector with Electrolyte Detection and Neutralizing spray to ensure that all traces of acid have been neutralized. NOTE: When the spray remains an orange color, any remaining battery acid has been neutralized. 2. Using compressed air, carefully blow out the connector until completely dry. 3. If previously disconnected, connect the large and/or small wiring harness connectors to the ABS control module. 4. Transfer the battery temperature sensor from the old battery tray to the new battery tray (Figure 14). Then discard the old battery tray. 5. Place a small bead of RTV silicone rubber adhesive (P/N 04883971) onto the base of the new drain tube grommet. 6. Snap the new drain tube into position on the new battery tray (Figure 14). 7. While installing the new battery tray into position, route the drain tube through the original hole in the fender panel (Figure 15) and connect the battery temperature sensor electrical connector. 8. Install the battery tray mounting bolts. Tighten the bolts to 95 in. lbs. (10.7 N.m). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4655 9. Install the battery onto the new battery tray. 10. Install the "J" hook and battery hold down bracket. 11. Install the battery hold down retaining nuts. Tighten the nuts to 24 in. lbs. (2.7 N.m). 12. Connect the positive battery cable to the positive battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 13. Connect the negative battery cable to the negative battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 14. From inside the left wheel well housing, secure the battery tray drain tube to the frame rail bracket with the provided plastic tie strap (Figure 16). 15. If the ABS control module was replaced, connect the DRB III scan tool to the vehicle and program the rear axle ratio and tire size into the new control module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4656 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > NHTSA04V185000 > Apr > 04 > Recall 04V185000: ABS Control Module Corrosion Electronic Brake Control Module: All Technical Service Bulletins Recall 04V185000: ABS Control Module Corrosion DEFECT: On some van and wagon model vehicles equipped with 4-wheel antilock brake systems (ABS), aftermarket batteries may leak electrolyte onto the ABS control module connector, which can compromise the sealing integrity of the connector. This may allow development of a short circuit in the connector, which could eventually lead to a fire. REMEDY: Dealers will inspect the ABS control module connector for electrolyte damage and replace the connector as necessary. The manufacturer has not yet provided an owner notification for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 18-002-02 > Jan > 02 > Rear Axle - Vehicle Speed Is Inaccurate Electronic Brake Control Module: All Technical Service Bulletins Rear Axle - Vehicle Speed Is Inaccurate NUMBER: 18-002-02 GROUP: Vehicle Performance DATE: January 21, 2002 THE MDS2(R) MUST BE OPERATING WITH CIS CD2094 OR HIGHER, AVAILABLE OCTOBER 29, 2001. THE DRBIII(R) MUST BE AT LEVEL 52.5 OR LATER. SUBJECT: Pinion Factor Recalibration MODELS: 1998-2002 AB Ram Van NOTE: THIS BULLETIN APPLIES TO ALL 1998 - 2002 (AB) RAM VANS EQUIPPED WITH THE 9.25 REAR AXLE. DISCUSSION: Owners of 1998 - 2002 (AB) Ram Vans equipped with the 9.25 rear axle may complain that vehicle speed is inaccurate. It may be that past service on the rear axle has caused the calibration to change. Accurate calibration can be restored by reprogramming the applicable module, (ABS) Antilock Brake System or (RWAL) Rear Wheel Antilock, using the DRBI III(R). NOTE: THE DRBIII(R) MUST BE AT LEVEL 52.5 OR HIGHER AND THE MDSII(R) AT CD 2094 OR HIGHER TO PERFORM THE REPROGRAMMING. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 18-002-02 > Jan > 02 > Rear Axle - Vehicle Speed Is Inaccurate Electronic Brake Control Module: All Technical Service Bulletins Rear Axle - Vehicle Speed Is Inaccurate NUMBER: 18-002-02 GROUP: Vehicle Performance DATE: January 21, 2002 THE MDS2(R) MUST BE OPERATING WITH CIS CD2094 OR HIGHER, AVAILABLE OCTOBER 29, 2001. THE DRBIII(R) MUST BE AT LEVEL 52.5 OR LATER. SUBJECT: Pinion Factor Recalibration MODELS: 1998-2002 AB Ram Van NOTE: THIS BULLETIN APPLIES TO ALL 1998 - 2002 (AB) RAM VANS EQUIPPED WITH THE 9.25 REAR AXLE. DISCUSSION: Owners of 1998 - 2002 (AB) Ram Vans equipped with the 9.25 rear axle may complain that vehicle speed is inaccurate. It may be that past service on the rear axle has caused the calibration to change. Accurate calibration can be restored by reprogramming the applicable module, (ABS) Antilock Brake System or (RWAL) Rear Wheel Antilock, using the DRBI III(R). NOTE: THE DRBIII(R) MUST BE AT LEVEL 52.5 OR HIGHER AND THE MDSII(R) AT CD 2094 OR HIGHER TO PERFORM THE REPROGRAMMING. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion Technical Service Bulletin # D20 Date: 040901 Recall - ABS Wiring Corrosion September 2004 Dealer Service Instructions for: Safety Recall D20 - ABS Wiring Corrosion Models 1998-2003 (AB) Dodge Ram Van/Wagon NOTE: This recall applies only to the above vehicles equipped with a 4-wheel Anti-lock Brake System (ABS) (sales code BGK). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject Electrolyte (battery acid) from aftermarket batteries may leak onto an Antilock Brake System (ABS) wiring connector on about 43,000 of the above vehicles. This may cause the wiring to corrode and short circuit, which can result in an underhood fire. Repair All vehicles must have a revised battery tray installed that will protect the ABS control module wiring harness connector from future electrolyte leakage. A cowl seal extension must also be installed on all vehicles to redirect any water draining from the windshield away from the battery. The ABS control module wiring harness and connector must be inspected for electrolyte damage and repaired if necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4675 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4676 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4677 Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Install Cowl Seal Extension 1. Open the hood. 2. Using Mopar glass cleaner and a shop cloth, clean the plastic cowl panel where the cowl seal ends on the driver's side of the vehicle (Figure 1). 3. Test fit the cowl seal extension. Cut the cowl seal extension length so that the seal stops at the end of the plastic cowl panel (Figure 1). 4. Insert the cowl seal connector halfway into the cowl seal extension (Figure 2). 5. Remove the protective plastic covering from the glue strip on the cowl seal extension. 6. Install the cowl seal extension connector into the original cowl seal end and firmly press the seal against the plastic cowl panel (Figure 2). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4678 7. Continue with Section B. Inspect ABS Control Module Wiring Harness Connector. B. Inspect ABS Control Module Wiring Harness Connector 1. Turn the ignition switch to the "Off" position. Be certain that all electrical accessories are turned off. 2. Loosen the battery negative cable clamp pinch-bolt hex nut. 3. Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 4. Loosen the battery positive cable terminal clamp pinch-bolt hex nut. 5. Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure 3). 6. Remove the two nuts with washers that secure the battery hold down strap to the threaded end of the J-bolt and the long stud (Figure 4). 7. Remove the battery hold down strap from the top of the battery (Figure 4). 8. Remove the J-bolt from the holes in the battery tray support on the inboard side of the battery tray (Figure 4). 9. Carefully remove the battery from the battery tray. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4679 WARNING: Wear a suitable pair of rubber gloves when removing the battery. Safety glasses should also be worn. 10. Remove the three screws that secure the bottom of the battery tray to the battery tray support (Figure 5). 11. Remove the two screws that secure the outboard side of the battery tray to the left cowl side panel (Figure 5). 12. Lift the battery tray slightly and disconnect the battery temperature sensor electrical connector. 13. Remove the battery tray and the drain tube from the vehicle as an assembly (Figure 5). 14. In the area below the battery location, inspect the front (large) wiring harness connector on the ABS control module for acid damage, by spraying the connector and surrounding area with the provided Electrolyte Detection and Neutralizing Spray (Figure 6). > If the spray remains an orange color, there is no electrolyte (battery acid) on the ABS control module wiring harness connector. Continue with Section E - Battery Tray Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4680 > If the spray turns a purple color, continue with Step 15 of this procedure. 15. Disconnect the large ABS control module wiring harness connector from the ABS control module by first sliding the red lock tab forward. Then push down on the black release tab while pulling the connector from the module (Figure 7). 16. Inspect the large ABS control module wiring harness connector: a. If a heat damaged (melted) connector is found, replace the wiring harness connector. Continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no heat damage is found continue with inspection Step b. b. Inspect the wire side and the terminal side of the large ABS control module wiring harness connector for green colored corrosion. If green colored corrosion is found in one or more of the connector cavities continue with Section C - ABS Control Module Wiring Harness Connector Replacement. If no green colored corrosion is found, continue with inspection Step c. c. Looking into the terminal side of the large ABS control module wiring harness connector, inspect the metal terminals for a dull finish or discoloration. If a dull finish or discoloration is found, continue with Section C - ABS Control Module Wiring Harness Connector Replacement because the original connector housing wire weather seals have been damaged. If no dull or discolored terminals are found continue with Section E - Battery Tray Installation. C. ABS Control Module Wiring Harness Connector Replacement NOTE: Only ABS control module wiring harness connectors with heat damage (melted), green wire terminals or dull/discolored terminals, as determined by the inspection in Section B, require replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4681 1. Remove the secondary terminal lock from the original ABS control module wiring harness connector housing (Figure 8). 2. Some models may have two empty wire cavities in the ABS control module wiring harness connector housing. Insert the gray wire cavity plugs supplied with the repair kit into the correct cavities of the new ABS control module wiring harness connector. 3. The ABS control module wiring harness connector terminals that do not have heat damage, green corrosion or are only dull or discolored can be transferred to the new connector using the following process: a. From the terminal side of the connector, insert a small pick into the connector next to the terminal and push on the terminal release arm while pulling on the wire. CAUTION: Remove only one wire from the original connector at a time and note which connector cavity the wire is to be transfer into. b. Using the electrolyte detection and neutralizing spray, lightly spray the removed wire until the spray remains an orange color. This may require two or three applications. c. Using compressed air, carefully dry the terminal and wire. d. Insert the terminal into the proper connector cavity of the new connector housing. e. Repeat Steps a. through d. on all wires that need to be transferred to the new connector housing. 4. The ABS control module wiring harness connector terminals with heat damage and/or green corrosion must be replaced using the following process: a. Cut off the wire one inch back from the original ABS connector. b. Remove one-half (1/2) inch (13 mm) of insulation from the wire on the harness that needs to be spliced. c. Cut the replacement wire supplied in the connector repair kit to the required length. Then remove one-half (1/2) inch (13 mm) of insulation from the wire. d. Place a piece of sealant lined heat shrink tubing on one side of the wire. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4682 e. Place the strands of wire overlapping each other inside of the brass splice band (Figure 9). f. Using crimp tool (Mopar P/N 05019912AA), crimp the brass splice band and wires together (Figure 10). g. Solder the connection together using rosin core type solder. DO NOT use acid core solder. CAUTION: All splices must be properly soldered. Failure to properly solder these wiring connectors can cause the ABS to become inoperative in the future. h. Center the shrink tubing over the splice joint. Using a heat gun, heat the surface of the shrink tubing until the shrink tubing is tightly sealed and sealant comes out of both ends of the shrink tubing (Figure 11). 5. After all of the terminals have been transferred or replaced, install the blue secondary terminal lock into the ABS control module wiring harness connector (Figure 8). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4683 6. Using a small mirror (Snap-on GA295 or equivalent), inspect the ABS control module connector pins for green corrosion and the connector housing for heat damage (Figure 12). > ABS control module connectors found with green corroded pins continue with Section D - ABS Control Module Replacement. > ABS control module connector housings found with heat damage continue with Section D - ABS Control Module Replacement. > ABS control module connectors found without heat damage or green corroded pins continue with Section E - Battery Tray Installation. D. ABS Control Module Replacement NOTE: Only ABS control modules with a heat damaged (melted) connector or green corroded connector pins, as determined by the inspection in Section B and C, require replacement. Very few vehicles are expected to require ABS control module replacement. 1. Disconnect the small ABS control module wiring connector from the ABS control module (Figure 13). 2. Remove the four mounting screws on the ABS control module (Figure 13). 3. Lift the module from the ABS hydraulic control unit and disconnect the solenoid connector located on the bottom side of the ABS control module. 4. Remove the ABS control module from the vehicle and discard. 5. Using a clean shop towel, clean the ABS control module mounting surface on the ABS hydraulic control unit. 6. Connect the solenoid connector to the new ABS control module and then place the module into position on the ABS hydraulic control unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4684 7. Install the four ABS control module mounting screws. Tighten the screws to 39 in. lbs (4.4 N.m). 8. Continue with Section E - Battery Tray Installation. E. Battery Tray Installation 1. If disconnected, spray the ABS control module connector and the ABS control module wiring harness connector with Electrolyte Detection and Neutralizing spray to ensure that all traces of acid have been neutralized. NOTE: When the spray remains an orange color, any remaining battery acid has been neutralized. 2. Using compressed air, carefully blow out the connector until completely dry. 3. If previously disconnected, connect the large and/or small wiring harness connectors to the ABS control module. 4. Transfer the battery temperature sensor from the old battery tray to the new battery tray (Figure 14). Then discard the old battery tray. 5. Place a small bead of RTV silicone rubber adhesive (P/N 04883971) onto the base of the new drain tube grommet. 6. Snap the new drain tube into position on the new battery tray (Figure 14). 7. While installing the new battery tray into position, route the drain tube through the original hole in the fender panel (Figure 15) and connect the battery temperature sensor electrical connector. 8. Install the battery tray mounting bolts. Tighten the bolts to 95 in. lbs. (10.7 N.m). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4685 9. Install the battery onto the new battery tray. 10. Install the "J" hook and battery hold down bracket. 11. Install the battery hold down retaining nuts. Tighten the nuts to 24 in. lbs. (2.7 N.m). 12. Connect the positive battery cable to the positive battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 13. Connect the negative battery cable to the negative battery post. Tighten the retaining nut to 70 in. lbs. (7.9 N.m). 14. From inside the left wheel well housing, secure the battery tray drain tube to the frame rail bracket with the provided plastic tie strap (Figure 16). 15. If the ABS control module was replaced, connect the DRB III scan tool to the vehicle and program the rear axle ratio and tire size into the new control module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4686 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > NHTSA04V185000 > Apr > 04 > Recall 04V185000: ABS Control Module Corrosion Electronic Brake Control Module: All Technical Service Bulletins Recall 04V185000: ABS Control Module Corrosion DEFECT: On some van and wagon model vehicles equipped with 4-wheel antilock brake systems (ABS), aftermarket batteries may leak electrolyte onto the ABS control module connector, which can compromise the sealing integrity of the connector. This may allow development of a short circuit in the connector, which could eventually lead to a fire. REMEDY: Dealers will inspect the ABS control module connector for electrolyte damage and replace the connector as necessary. The manufacturer has not yet provided an owner notification for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > With RWAL Brakes Electronic Brake Control Module: Specifications With RWAL Brakes Mounting Screws ................................................................................................................................. ....................................................... 4 Nm (36 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > With RWAL Brakes > Page 4693 Electronic Brake Control Module: Specifications With 4-Wheel Antilock Brakes Screws ................................................................................................................................................. ................................................. 4.4 Nm (39 inch lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > EBC 2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > EBC 2 > Page 4696 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock Brake (CAB) Electronic Brake Control Module: Description and Operation Kelsey-Hayes EBC Controller Antilock Brake (CAB) The CAB is mounted under the hood, separately from the valve body, and has a microprocessor and circuits that: - monitor the brake switch input to tell whether or not to prepare for possible antilock braking - monitor the wheel speed sensor inputs to determine when a rear wheel is tending to lock up. - operate the integral control unit assembly during antilock braking based on comparing the speed sensor to information programmed in memory - detect ABS system related problems and take diagnostic action The CAB will disable antilock control and set a hard ignition latched trouble code if it detects one of the following conditions with itself: - (71) RAM Read/Write - (72) ROM Checksum - (73) Watchdog Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock Brake (CAB) > Page 4699 Electronic Brake Control Module: Description and Operation Kelsey-Hayes EBC 325 Controller Antilock Brake (CAB) The CAB is mounted directly to the hydraulic control unit and includes a microprocessor and six solenoids that control brake pressure during antilock braking. The CAB also has circuits that monitor the following: - Brake switch input is monitored to determine whether or not to prepare for possible antilock braking. - Wheel speed sensors are monitored to determine when a wheel is tending to lock up. The CAB will operate the valves in the ECU to control braking pressure during antilock braking. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock Brake (CAB) > Page 4700 Electronic Brake Control Module: Description and Operation With Four Wheel Antilock Brakes CAB/HCU The Controller Antilock Brake (CAB) is mounted on the top of the hydraulic control unit. The CAB operates the ABS system and is separate from other vehicle electrical circuits. CAB voltage source is through the ignition switch in the RUN position. The CAB contains dual microprocessors. A logic block in each microprocessor receives identical sensor signals. These signals are processed and compared simultaneously. The CAB contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the DRB scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock Brake (CAB) > Page 4701 Electronic Brake Control Module: Description and Operation With Rear Wheel Antilock Brakes GENERAL INFORMATION RWAL Controller Antilock Brake (CAB) The Controller Antilock Brakes (CAB) is a microprocessor which handles testing, monitoring and controlling the ABS brake system operation. The CAB functions are: Perform self-test diagnostics. - Monitors the RWAL brake system for proper operation. - Controls the RWAL valve solenoids. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. SYSTEM SELF-TEST When the ignition switch is turned-on the microprocessor RAM and ROM are tested. If an error occurs during the test a Diagnostic Trouble Code (DTC) will be set into the RAM memory. However it is possible the DTC will not be stored in memory if the error has occurred in the RAM module were the DTC's are stored. Also it is possible a DTC may not be stored if the error has occurred in the ROM which signals the RAM to store the DTC. CAB INPUTS The CAB continuously monitors the speed of the differential ring gear by monitoring signals generated by the rear wheel speed sensor. The CAB determines a wheel locking tendency when it recognizes the ring gear decelerating too rapidly. The CAB monitors the following inputs to determine when a wheel locking tendency may exists: - Rear Wheel Speed Sensor - Brake Lamp Switch - Brake Warning Lamp Switch - Reset Switch - 4WD Switch (If equipped) CAB OUTPUTS The CAB controls the following outputs for antilock braking and brake warning information: RWAL Valve - ABS Warning Lamp - Brake Warning Lamp Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System Electronic Brake Control Module: Service and Repair Four Wheel Antilock Brake System NOTE: If the Controller Antilock Brake (CAB) needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. REMOVAL 1. Disconnect battery cables and remove the battery. 2. Remove the power distribution center. 3. Remove the battery and power distribution center mount. 4. Remove the washer reservoir mounting screws. 5. Lift up the reservoir and disconnect the pump motor connector and pump hose. 6. Remove the reservoir from the engine compartment. Harness Connector Locks 7. Push the harness connector locks to release the locks, then remove the connectors from the CAB. Pump Motor Connector 8. Disconnect the pump motor connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 4704 Controller Mounting Screws 9. Remove screws attaching CAB to the Hydraulic Control Unit (HCU). 10. Remove the CAB. INSTALLATION 1. Place the CAB onto the HCU. NOTE: Insure the CAB seal is in position before installation. 2. Install the mounting screws and tighten to 4.4 Nm (39 inch lbs.). 3. Connect the pump motor harness. 4. Connect the harnesses to the CAB and lock the connectors. 5. Install the reservoir in the engine compartment. Connect the pump motor connector and pump hose. 6. Install the washer reservoir mounting screws. 7. Install the battery and power distribution center mount. 8. Install the power distribution center. 9. Install the battery and battery cables. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 4705 Electronic Brake Control Module: Service and Repair Rear Wheel Antilock Brake System NOTE: If the Controller Antilock Brake (CAB) needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. REMOVAL 1. Remove the washer reservoir mounting screws. 2. Lift up the reservoir and disconnect the pump motor connector and pump hose. 3. Remove the reservoir from the engine compartment. 4. Disconnect battery cables and remove the battery. 5. Remove the power distribution center. 6. Remove the battery and power distribution center mount. 7. Remove the RWAL valve harness. 8. Pull up on the CAB harness connector lock release and remove the connector from the controller. 9. Remove controller mounting screws and remove controller. INSTALLATION 1. Position the controller on the mounting bracket and install the mounting screws. 2. Install the CAB harness connector into the controller and push down on the connector lock. 3. Install the RWAL valve harness connector into controller. 4. Install the battery and power distribution center mount. 5. Install the power distribution center. 6. Install the battery and battery cables. 7. Install the reservoir in the engine compartment. Connect the pump motor connector and pump hose. 8. Install the washer reservoir mounting screws. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > 4WD Switch > Component Information > Description and Operation 4WD Switch: Description and Operation Vehicles equipped with four wheel drive (4WD) have an indicator switch mounted on the front axle assembly. This switch is closed to ground when the transfer case is shifted to four wheel drive mode and the engine is running on some vehicles. While in four wheel drive, the front and rear axles will operate together. With this input, the CAB is able to modify its operation to allow for 4WD operation. Should a need for antilock operation occur while in four wheel drive, the CAB will extend the amount of allowable dump cycles. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Description and Operation Braking Sensor/Switch: Description and Operation An input from this switch prepares the CAB for a possible antilock stop. The antilock system uses an input signal from the brake pedal activated switch. When the driver applies the brake pedal, the circuit voltage is 12 volts. A released brake pedal will close the switch circuit and provide O volts. This signal tells the CAB that the pedal is depressed Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > With Four Wheel Antilock Brakes Wheel Speed Sensor: Specifications Front Bolt 11 ft.lb Rear Bolt 18 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > With Four Wheel Antilock Brakes > Page 4717 Wheel Speed Sensor: Specifications Mounting Bolt 18 ft.lb Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4720 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4721 Wheel Speed Sensor: Connector Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 4724 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brakes OPERATION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front steering knuckles. The third sensor is mounted on top of the rear axle differential housing. The sensor is a magnet coil that is mounted over a tone wheel front/exciter ring rear with an air gap between them. The sensors measure the wheel speed by monitoring the rotation of the tone wheels front/exciter ring rear. As the teeth of the tone wheels front/exciter ring rear move through the magnetic field of the sensor an AC voltage is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The Controller Antilock Brake (CAB) monitors these signals for changes in wheel deceleration. If the CAB detects a sudden wheel or wheels deceleration within a predetermined amount the CAB will activate the ABS system. CIRCUIT OPERATION The all wheel Anti-Lock Brake System (ABS) uses three wheel speed sensors; a single sensor for both rear wheels and individual sensors for the front wheels. The single sensor used for the rear wheels mounts on the top of the rear axle differential housing. Each sensor converts wheel speed into an electrical signal that is transmitted to the Controller Anti-Lock Brakes (CAB). A pair of twisted wires connect to each sensor and provide signals to the CAB. Circuits B6 and B7 provide signals to the CAB from the right front wheel speed sensor. Circuit B6, which provides the LOW signal, connects to cavity 15 of the CAB. Circuit B7 connects to cavity 2 of the CAB and provides the HIGH signal. Circuits B8 and B9 provide signals to the CAB from the left front wheel speed sensor. Circuit B8, which provides the LOW signal, connects to cavity 16 of the CAB. Circuit B9 connects to cavity 3 and provides the HIGH signal. Circuit B114 connects to cavity 14 of the CAB and to circuit B2 of the rear wheel speed sensor harness at the sensor connector. Circuit B113 connects to cavity 1 of the CAB and to circuit B1 at the rear wheel speed sensor harness connector. Circuit B114 provides the rear wheel speed sensor LOW input while circuit B113 provides the HIGH input. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 4727 Wheel Speed Sensor: Description and Operation Kelsey-Hayes Antilock Brake Systems The EBC 325 ABS system uses one wheel speed sensor on each front wheel, and one speed sensor mounted in the rear axle for the rear wheels. The RWAL II uses only one speed sensor mounted in the rear axle for the rear wheels. The sensor measures the wheel speed by monitoring a rotating tone wheel. The signal generated by the sensor and tone wheel is transmitted to the CAB. Each sensor has: - a metal tone wheel with teeth on its outside diameter - a magnetic/coil pick-up (speed sensor) that is mounted to a fixed component - an air gap between the tone wheel and the speed sensor assembly As the teeth of the tone wheel move through the magnetic field of the sensor, an AC voltage is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The CAB monitors this signal to check for a sudden change in single or multiple wheel decelerations. If the deceleration of one or more wheels is not within a predetermined amount, the antilock module takes control. Diagnostically, the coil of wheel speed sensors have different amounts of resistance based upon the sensor type. When measured across the connector two terminals, the resistance should be: AN, DN, BE and BR: 4x4 front sensors 945-1155 ohms AB, AN and DN: 4x2 front sensors 2500-2955 ohms BE and BR: 4x2 front sensors 1000-1250 ohms AB, AN, DN, BE and BR: All rear sensors 1600-2300 ohms NOTE: For all resistance ranges add 30% to the value for extreme heat, subtract 30% for extreme cold.) The rear wheel speed sensor used on all vehicles have the same resistance value, but there are two different sensors. Therefore, it is important to replace the rear wheel speed sensor with the proper part. On a EBC 325 system each front wheel speed is monitored through the speed sensor mounted at the wheel end of the hub. On a EBC 325 and RWAL II system the rear wheel speed is monitored through the speed sensor mounted in the rear axle assembly. The CAB will disable antilock control, illuminate the ABS warning light circuit via COD, and store trouble codes if it detects a problem with any or all of the wheel speed sensors: - incorrect circuit resistance when checked with no vehicle movement - incorrect sensor output during vehicle movement - erratic sensor output during vehicle movement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 4728 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brakes The rear wheel speed sensor is mounted on the top of the rear axle differential. The sensor converts wheel speed into an electrical signal that is transmitted to the Rear Wheel Anti-Lock (RWAL) control module. Circuits B113 and B114, a pair of twisted wires connect to the sensor and provide signals to the RWAL control module. These circuits also connect to the rolls test connector used only during manufacture of the vehicle. Circuit B113 connects to cavity 14 of the RWAL control module and to circuit B1 of the wheel speed sensor harness. Circuit B114 connects to cavity 13 of the RWAL control module and circuit B2 of the sensor harness. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Front REMOVAL 1. Raise and support vehicle. 2. Disconnect speed sensor from the main harness. Wheel Speed Sensor 3. Remove sensor mounting bolt from the steering knuckle. 4. Remove the sensor from the steering knuckle. INSTALLATION CAUTION: A special bolt is used to attach the sensor. Use only a factory replacement bolt. 1. Install the sensor into the steering knuckle. 2. Install mounting bolt and tighten to 15 Nm (11 ft. lbs.). 3. Connect sensor wire to main harness and ensure wire is routed away from hot or moving components. 4. Remove supports and lower vehicle. With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4731 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 0-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. With Four Wheel Antilock Brakes REMOVAL 1. Raise and support vehicle. Rear Wheel Speed Sensor 2. Disconnect wire from rear sensor on axle housing. 3. Remove sensor and bracket mounting bolt and remove sensor and bracket. INSTALLATION 1. Secure sensor wire to rear brake hose with clips provided. 2. Install sensor and mounting bracket in axle housing. Install mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Connect wire to sensor and secure wire to mounting bracket. 4. Remove support and lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4732 Wheel Speed Sensor: Service and Repair Tone Wheel Replacement Front Tone Wheel Tone Wheel The tone wheel for the front speed sensor is located on the rotor hub. The tone wheel is not a serviceable component. The complete rotor and hub assembly will have to be replaced if the tone wheel is damaged. Rear Tone Wheel The toothed exciter ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, refer to Transmission and Drivetrain for service procedures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Tray, Battery Tempt Sensor, Engine Wiring Harness, Sensor Harness Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4738 Battery Temperature Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4739 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4740 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry. refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pig-tail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 4743 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. Refer to Starting and Charging/Battery 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Refer to Starting and Charging/Battery Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For electrical diagnosis of the Key-In-Switch, For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Replacement. On vehicles equipped with an automatic transmission and a steering column mounted shifter, an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. On vehicles equipped with an automatic transmission and a floor mounted shifter, a cable connects the interlock device within the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. The shifter interlock cable can be adjusted or replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4748 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative battery cable from battery. 2. Place shifter in PARK position. 3. Remove tilt-wheel lever (pulls out). Lower Shroud Screws 4. Remove 2 lower shroud screws (size T25). Shroud Pivot Point 5. Upper and lower shrouds are snapped together at sides. Pivot points for lower and upper shrouds is at rear of shrouds. Lower shroud is hooked to pins on upper shroud. Tilt lower shroud down for removal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4749 Upper Shroud Screws 6. Remove 2 upper shroud screws (size T5) and remove upper shroud from steering column. 7. If removing key lock cylinder only, proceed to next step. If removing ignition switch, proceed to IGNITION SWITCH REMOVAL. 8. KEY LOCK CYLINDER REMOVAL: Ignition key must be in key cylinder for cylinder removal. a. Rotate and hold key in START position. Lock Cylinder Retainer Pin Access Hole b. Position a 1/16" pin punch into lock cylinder retainer pin access hole. c. Press in on pin punch to release lock cylinder retainer pin while releasing key to RUN position. d. Pull lock cylinder out for removal. 9. IGNITION SWITCH REMOVAL: Key lock cylinder removal is not necessary for ignition switch removal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4750 Installing Lock Cylinder To Column Removing/Installing Alarm Switch a. Remove alarm switch. Alarm switch is located at right/upper side of steering column. Press on retaining clip with a small screwdriver while rotating switch 1/4 turn for removal. b. Remove knee blocker below steering column. Refer to Knee Blocker in Instrument Panel Gauges And Warning Indicator. c. Note position of wiring harnesses and all tie wraps between ignition switch and 4 way connector at lower part of steering column. when installing ignition switch/wire harness assembly, the harnesses must be correctly routed with tie wraps in correct position to prevent damage to harness. d. If equipped with overdrive (OD) transmission, unclip OD wire harness at ignition switch. e. Cut necessary tie wraps. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4751 Ignition Switch Mounting Screws f. Remove 2 ignition switch mounting screws (size T4) and separate switch at steering column. Separating 48-Way Connectors At Lower Part Of Column g. Separate steering column 48-way electrical connectors by removing one fastener (bolt). The 48-way connector is located near lower part of steering column. This 48-way connector contains 48 different pin-outs including 3 different connectors: a 17-way for the multi-function switch; a 13-way for the multi-function switch; and an 18-way for the ignition switch. Separating 48-Way Connectors At Lower Part Of Column h. Separate 17-way multi-function switch connector from 18-way ignition switch connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4752 Steering Column 48-Way Connector (Male C0nnector To Column Shown) i. Separate 13-way multi-function switch connector from 18-way ignition switch connector. j. Separate multi-function switch wire harnesses from ignition switch wiring harness. k. Remove wiring harness and ignition switch as an assembly from steering column. INSTALLATION 1. KEY LOCK CYLINDER INSTALLATION: a. Place key into lock cylinder. b. Place key lock cylinder into steering column by aligning positioning tab on lock cylinder to positioning slot on steering column. Locking tab should also be aligned to locking tab slot. c. Press on lock cylinder until retaining pin engages. d. Rotate key to OFF position. e. Check for proper retention of lock cylinder by attempting to pull out on lock cylinder. 2. IGNITION SWITCH INSTALLATION: a. Position switch and wire harness assembly to steering column. b. Install switch screws and tighten to 1.4 N.m (12 in. lbs.) torque. c. Carefully route ignition switch wire harness down to bottom of steering column. d. If equipped with overdrive (OD) transmission, clip OD wire harness to ignition switch. e. Route alarm switch wire harness around ignition switch. f. Attach alarm switch to steering column by rotating and snapping into position). g. Attach 13-way multi-function switch connector to ignition switch 18-way connector. h. Attach 17-way multi-function switch connector to ignition switch 18-way connector. i. Attach both 48-way electrical connectors together (1 bolt). Tighten bolt to 7 N.m (62 in. lbs.) torque. j. Install new tie wraps in their previously noted positions. k. If equipped with a tilt steering wheel, operate tilt mechanism while observing wiring harnesses for binding. Correct binding if necessary. l. Operate shift lever while observing wiring harnesses for binding. Correct binding if necessary. 3. A 2-5/8" long plastic spacer is attached to inside of upper shroud. Before positioning shroud to column, verify spacer is tightened to upper shroud. 4. Position upper shroud to steering column. 5. Install 2 upper shroud screws. 6. Position rubber shields for shift lever and multi-function switch into upper shroud. 7. Position lower shroud hooks into pins on upper shroud. 8. Snap lower shroud to upper shroud. 9. Install 2 lower shroud screws. 10. Install tilt-wheel lever (snaps in). 11. Shifter should lock in PARK position when key is in LOCK position. Shifter should unlock when key rotated to ON position. 12. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 13. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify Steering wheel should unlock when key is rotated to ON position. 14. Connect negative battery cable to battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Switch, Park/Neutral ............................................................................................................................ ..................................................... 34 Nm (25 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 4756 Solenoid Case Connector, Park/Neutral Position Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 4757 Park/Neutral Position Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair > 32RH Transmission Neutral Safety Switch: Service and Repair 32RH Transmission REMOVAL 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. INSTALLATION Park/Neutral Position Switch 1. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 2. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 3. Test continuity of new switch with 12V test lamp. 4. Connect switch wires and lower vehicle. 5. Top off transmission fluid level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair > 32RH Transmission > Page 4760 Neutral Safety Switch: Service and Repair 46RE Transmission REMOVAL 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. INSTALLATION Park/Neutral Position Switch 1. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 2. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 3. Test continuity of new switch with 12V test lamp. 4. Connect switch wires and lower vehicle. 5. Top off transmission fluid level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4765 Starter Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4766 Starter Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4767 Starter Relay: Description and Operation SYSTEM OPERATION The starter relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay However, the micro-relay terminal orientation (or footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The starter relay is a electromechanical device that switches battery current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. See Starter Relay/Testing and Inspection/Procedures. The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. The starter relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4768 Starter Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for starter relay identification and location. 4. Unplug the starter relay from the PDC. 5. Install the starter relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations Battery Tray, Battery Tempt Sensor, Engine Wiring Harness, Sensor Harness Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4773 Battery Temperature Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4774 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4775 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry. refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pig-tail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 4778 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. Refer to Starting and Charging/Battery 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Refer to Starting and Charging/Battery Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Voltage Alternator: Specifications Voltage Powertrain Control Module (PCM) regulates charging system voltage by controlling the generator field source (+) circuit. The voltage range is 12.9 to 15.0 volts Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Voltage > Page 4784 Alternator: Specifications Rated Amps Denso Part # 56027912 Rated SAE Amps .......................................................................................... .......................................................................................................... 117 amps Minimum Test Amps ............................................................................................................................ ..................................................................... 90 amps Denso Part # 56027913 Rated SAE Amps .......................................................................................... .......................................................................................................... 136 amps Minimum Test Amps ............................................................................................................................ ................................................................... 120 amps Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4785 B+terminal,ground Terminal,generator Field Connections Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4786 Alternator: Description and Operation SYSTEM OPERATION The generator is belt-driven by the engine using a serpentine type drive belt. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must he replaced. As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the generator begins producing sufficient current. it also provides the current needed to energize the rotor. The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicle electrical system through the generator battery and ground terminals. Although the generators appear the same externally, different generators with different output ratings are used on this vehicle. Be certain that the replacement generator has the same output rating and part number as the original unit. Refer to Generator Ratings in the Specifications for amperage ratings and part numbers. Noise emitting from the generator may be caused by: worn, loose or defective bearings; a loose or defective drive pulley; incorrect, worn, damaged or misadjusted fan drive belt; loose mounting bolts; a misaligned drive pulley or a defective stator or diode. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4787 Alternator: Service and Repair REMOVAL WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM. 1. Disconnect negative battery cable at battery 2. Remove generator drive belt. Remove/Install Generator 3. Remove generator pivot and mounting bolts/nut. Position generator for access to wire connectors. Remove/Install Generator Connectors - Typical 4. Remove nuts from harness holddown, battery terminal, ground terminal and 2 field terminals. Remove wire connectors. A typical generator wiring harness is shown. Wiring harness routing as shown may be slightly different depending on vehicle model and/or engine. 5. Remove generator from vehicle. INSTALLATION 1. Position generator to engine and install wiring to rear of generator. Tighten all wiring fasteners as follows: - Battery terminal nut 8.5 N.m (75 in. lbs.) - Ground terminal nut-8.5 N.m (75 in. lbs.) - Field terminal nuts 2.8 N.m (25 iii. lbs.) 2. Install generator mounting fasteners and tighten as follows: - Generator mounting bolt-41 N.m (30 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4788 - Generator pivot bolt/nut-41 N.m (30 ft. lbs.) CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged. - When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. 3. Install generator drive belt. 4. Install negative battery cable to battery Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation Voltage Regulator: Description and Operation SYSTEM OPERATION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. Operation: The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage and battery temperature (refer to Battery Temperature Sensor for more information). It then compensates and regulates generator current output accordingly. Also refer to Charging System Operation for additional information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For electrical diagnosis of the Key-In-Switch, For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Replacement. On vehicles equipped with an automatic transmission and a steering column mounted shifter, an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. On vehicles equipped with an automatic transmission and a floor mounted shifter, a cable connects the interlock device within the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. The shifter interlock cable can be adjusted or replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4797 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative battery cable from battery. 2. Place shifter in PARK position. 3. Remove tilt-wheel lever (pulls out). Lower Shroud Screws 4. Remove 2 lower shroud screws (size T25). Shroud Pivot Point 5. Upper and lower shrouds are snapped together at sides. Pivot points for lower and upper shrouds is at rear of shrouds. Lower shroud is hooked to pins on upper shroud. Tilt lower shroud down for removal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4798 Upper Shroud Screws 6. Remove 2 upper shroud screws (size T5) and remove upper shroud from steering column. 7. If removing key lock cylinder only, proceed to next step. If removing ignition switch, proceed to IGNITION SWITCH REMOVAL. 8. KEY LOCK CYLINDER REMOVAL: Ignition key must be in key cylinder for cylinder removal. a. Rotate and hold key in START position. Lock Cylinder Retainer Pin Access Hole b. Position a 1/16" pin punch into lock cylinder retainer pin access hole. c. Press in on pin punch to release lock cylinder retainer pin while releasing key to RUN position. d. Pull lock cylinder out for removal. 9. IGNITION SWITCH REMOVAL: Key lock cylinder removal is not necessary for ignition switch removal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4799 Installing Lock Cylinder To Column Removing/Installing Alarm Switch a. Remove alarm switch. Alarm switch is located at right/upper side of steering column. Press on retaining clip with a small screwdriver while rotating switch 1/4 turn for removal. b. Remove knee blocker below steering column. Refer to Knee Blocker in Instrument Panel Gauges And Warning Indicator. c. Note position of wiring harnesses and all tie wraps between ignition switch and 4 way connector at lower part of steering column. when installing ignition switch/wire harness assembly, the harnesses must be correctly routed with tie wraps in correct position to prevent damage to harness. d. If equipped with overdrive (OD) transmission, unclip OD wire harness at ignition switch. e. Cut necessary tie wraps. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4800 Ignition Switch Mounting Screws f. Remove 2 ignition switch mounting screws (size T4) and separate switch at steering column. Separating 48-Way Connectors At Lower Part Of Column g. Separate steering column 48-way electrical connectors by removing one fastener (bolt). The 48-way connector is located near lower part of steering column. This 48-way connector contains 48 different pin-outs including 3 different connectors: a 17-way for the multi-function switch; a 13-way for the multi-function switch; and an 18-way for the ignition switch. Separating 48-Way Connectors At Lower Part Of Column h. Separate 17-way multi-function switch connector from 18-way ignition switch connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4801 Steering Column 48-Way Connector (Male C0nnector To Column Shown) i. Separate 13-way multi-function switch connector from 18-way ignition switch connector. j. Separate multi-function switch wire harnesses from ignition switch wiring harness. k. Remove wiring harness and ignition switch as an assembly from steering column. INSTALLATION 1. KEY LOCK CYLINDER INSTALLATION: a. Place key into lock cylinder. b. Place key lock cylinder into steering column by aligning positioning tab on lock cylinder to positioning slot on steering column. Locking tab should also be aligned to locking tab slot. c. Press on lock cylinder until retaining pin engages. d. Rotate key to OFF position. e. Check for proper retention of lock cylinder by attempting to pull out on lock cylinder. 2. IGNITION SWITCH INSTALLATION: a. Position switch and wire harness assembly to steering column. b. Install switch screws and tighten to 1.4 N.m (12 in. lbs.) torque. c. Carefully route ignition switch wire harness down to bottom of steering column. d. If equipped with overdrive (OD) transmission, clip OD wire harness to ignition switch. e. Route alarm switch wire harness around ignition switch. f. Attach alarm switch to steering column by rotating and snapping into position). g. Attach 13-way multi-function switch connector to ignition switch 18-way connector. h. Attach 17-way multi-function switch connector to ignition switch 18-way connector. i. Attach both 48-way electrical connectors together (1 bolt). Tighten bolt to 7 N.m (62 in. lbs.) torque. j. Install new tie wraps in their previously noted positions. k. If equipped with a tilt steering wheel, operate tilt mechanism while observing wiring harnesses for binding. Correct binding if necessary. l. Operate shift lever while observing wiring harnesses for binding. Correct binding if necessary. 3. A 2-5/8" long plastic spacer is attached to inside of upper shroud. Before positioning shroud to column, verify spacer is tightened to upper shroud. 4. Position upper shroud to steering column. 5. Install 2 upper shroud screws. 6. Position rubber shields for shift lever and multi-function switch into upper shroud. 7. Position lower shroud hooks into pins on upper shroud. 8. Snap lower shroud to upper shroud. 9. Install 2 lower shroud screws. 10. Install tilt-wheel lever (snaps in). 11. Shifter should lock in PARK position when key is in LOCK position. Shifter should unlock when key rotated to ON position. 12. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 13. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify Steering wheel should unlock when key is rotated to ON position. 14. Connect negative battery cable to battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Switch, Park/Neutral ............................................................................................................................ ..................................................... 34 Nm (25 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications > Page 4805 Solenoid Case Connector, Park/Neutral Position Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications > Page 4806 Park/Neutral Position Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Service and Repair > 32RH Transmission Neutral Safety Switch: Service and Repair 32RH Transmission REMOVAL 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. INSTALLATION Park/Neutral Position Switch 1. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 2. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 3. Test continuity of new switch with 12V test lamp. 4. Connect switch wires and lower vehicle. 5. Top off transmission fluid level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Service and Repair > 32RH Transmission > Page 4809 Neutral Safety Switch: Service and Repair 46RE Transmission REMOVAL 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. INSTALLATION Park/Neutral Position Switch 1. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 2. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 3. Test continuity of new switch with 12V test lamp. 4. Connect switch wires and lower vehicle. 5. Top off transmission fluid level. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Description and Operation Starter Motor: Description and Operation SYSTEM OPERATION The starter motor incorporates several features to create a reliable, efficient, compact, and lightweight unit. A planetary gear system (intermediate transmission) is used between the electric motor and the pinion gear. This feature makes it possible to reduce the dimensions of the starter. At the same time, it allows higher armature rotational speed and delivers increased torque through the pinion gear to the starter ring gear on the automatic transmission torque converter. The starter motors for all engines are activated by a solenoid mounted to the overrunning clutch housing. However, the starter motor and solenoid are serviced only as a complete assembly If either component is faulty or damaged, the entire starter assembly must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Description and Operation > Page 4813 Starter Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. Starter Remove/Install 3. Remove the nut and lock washer from the starter mounting stud. Slide the automatic transmission cooler tube bracket forward on the tubes far enough for clearance. 4. Remove the screw from the upper starter mounting flange hole. 5. Move the starter towards the front & the vehicle until the starter gear housing nose clears the bell-housing. Then tilt the nose downwards and tower the starter far enough to access the starter solenoid wire harness connection 6. Remove the two nuts that secure the battery cable and solenoid feed wire to the terminals on the starter solenoid. Remove the starter solenoid wire harness connector from the solenoid terminals. 7. Remove the starter motor from the vehicle. 8. Reverse the removal procedures to install. Tighten the starter hardware as follows: - Lower mounting nut - 68 N.m (50 ft. lbs.) - Upper mounting screw - 68 N.m (50 ft. lbs.) - Battery cable terminal nut - 14 N.m (120 in. lbs.) - Solenoid wire harness terminal nut - 6 N.m (55 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4817 Starter Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4818 Starter Relay Connector, PDC Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4819 Starter Relay: Description and Operation SYSTEM OPERATION The starter relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay However, the micro-relay terminal orientation (or footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The starter relay is a electromechanical device that switches battery current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. See Starter Relay/Testing and Inspection/Procedures. The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. The starter relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4820 Starter Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for starter relay identification and location. 4. Unplug the starter relay from the PDC. 5. Install the starter relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4826 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4827 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4828 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4829 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4830 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4831 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4832 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4833 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4834 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4835 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4836 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4837 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4838 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4839 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4840 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4841 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4842 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4843 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4844 Auxiliary Power Outlet: Description and Operation SYSTEM OPERATION An accessory power outlet is optional equipment on this model. The power outlet is installed in the instrument panel accessory switch plate, which is located near the center of the instrument panel, inboard of the radio. The power outlet base is secured by a snap fit within the instrument panel accessory switch plate. A plastic protective cap snaps into the power outlet base when the power outlet is not being used. The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the Power Distribution Center (PDC) at all times. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4845 Auxiliary Power Outlet: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the Power Distribution Center (PDC). If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the PDC. If OK, go to Step 4. If not OK, repair the open circuit to the battery as required. 3. Remove the plastic protective cap from the power outlet receptacle. Check for continuity between the inside circumference of the power outlet receptacle and a good ground. There should be continuity. If OK, go to Step 5. If not OK, go to Step 6. 4. Check for battery voltage at the insulated contact located at the back of the power outlet receptacle. If not OK, go to Step 6. 5. Disconnect and isolate the battery negative cable. Remove the instrument panel accessory switch plate. Check for continuity between the ground circuit cavity of the power outlet wire harness connector and a good ground. There should be continuity. If OK, go to Step 7. If not OK, repair the open circuit to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power outlet wire harness connector. If OK, replace the faulty power outlet receptacle. If not OK, repair the open circuit to the PDC fuse as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4846 Auxiliary Power Outlet: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Cigar Lighter And Power Outlet 2. Unsnap the power outlet protective cap from the power outlet receptacle base. Power Outlet Remove/Install - Typical 3. Look inside the power outlet receptacle base and note the position of the rectangular retaining bosses of the mount that secures the receptacle base to the instrument panel accessory switch plate. 4. Insert a pair of external snap ring pliers into the power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of tile mount. 6. Remove the power outlet mount from the instrument panel accessory switch plate. 7. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Description and Operation Circuit Breaker: Description and Operation SYSTEM OPERATION An automatic resetting circuit breaker in the junction block is used to protect the power seat system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck seat adjuster. The circuit breaker cannot be repaired and, if faulty or damaged, it must be replaced. An automatic resetting circuit breaker in the junction block is used to protect the power window system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck window glass or regulator. The circuit breaker cannot be repaired and, if faulty, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Description and Operation > Page 4850 Circuit Breaker: Testing and Inspection 1. Locate the correct circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Description and Operation > Page 4851 Circuit Breaker: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the end cap from the driver side end of the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel End Cap. Junction Block 3. Unplug the circuit breaker from the junction block. 4. Install the circuit breaker by aligning its terminals with the cavities in the junction block and pushing the circuit breaker firmly into place. 5. Connect the battery negative cable. 6. Test the circuit breaker operation. 7. Reinstall the end cap on the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel End Cap. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Description and Operation Electronic Noise Suppressor: Description and Operation SYSTEM OPERATION Radio Frequency Interference (RFI) and ElectroMagnetic Interference (EMI) noise suppression is accomplished primarily through circuitry internal to the radio receivers. These internal suppression devices are only serviced as part of the radio receiver. External suppression devices that are serviced, and should be checked in the case of RFI or EMI noise complaints, include the following: Radio antenna base ground - Radio chassis ground wire, strap, or bracket - Engine-to-body ground strap (if the vehicle is so equipped) - Cab-to-bed ground strap (if the vehicle is so equipped) - Heater core ground strap (if the vehicle is so equipped) - Resistor-type spark plugs - Radio suppression-type secondary ignition wiring. In addition, if the source of RFI or EMI noise is identified as a component on the vehicle (i.e., generator, blower motor, etc.), the ground path for that component should be checked. If excessive resistance is found in that circuit, repair that circuit as required before considering any component replacement. If the source of the noise is identified as two-way mobile radio or telephone equipment, check the equipment installation for the following: Power connections should be made directly to the battery, and fused as closely to the battery as possible. - The antenna should be mounted on the roof or toward the rear of the vehicle. Remember that magnetic antenna mounts on the roof panel can adversely affect the operation of an overhead console compass, if the vehicle is so equipped. - The antenna cable should be fully shielded coaxial cable, should be as short as is practical, and should be routed away from the factory-installed vehicle wire harnesses whenever possible. - The antenna and cable must be carefully matched to ensure a low Standing Wave Ratio (SWR). Fleet vehicles are available with an extra-cost RFI suppressed Powertrain Control Module (PCM). This unit reduces interference generated by the PCM on some radio frequencies used in two-way radio communications. However, this unit will not resolve complaints of RFI in the commercial AM or FM radio frequency ranges Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Power Distribution Center > Page 4859 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions Multiple Junction Connector: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4864 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4865 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4866 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4867 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4868 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4869 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4870 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4871 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4872 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4873 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4874 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4875 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4876 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4877 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4878 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4879 Multiple Junction Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4880 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4881 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4882 Multiple Junction Connector: Electrical Diagrams 8w-12-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4883 8w-12-3 Diagrams Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4884 8w-12-6 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4885 8w-12-7 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4886 8w-12-8 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4887 8w-12-9 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4888 8w-12-10 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4889 8w-12-11 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4890 8w-12-12 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4891 8w-12-13 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4892 8w-12-14 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4893 8w-12-15 NOTE: To view Diagrams referred to in these diagrams SEE Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Page 4894 Multiple Junction Connector: Service and Repair Junction Block REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the knee blocker from the instrument panel. See Knee Blocker Replacement. 3. Reach through the outboard side of the instrument panel steering column opening to access and unplug all of the wire harness connectors from the junction block cavities. Junction Block Remove/Install 4. With the driver side front door open, remove the two screws that secure the junction block to the left instrument panel end bracket. 5. Reach through the outboard side of the instrument panel steering column opening to remove the junction block from the left instrument panel end bracket. 6. Reverse the removal procedures to install. Tighten the mounting screws to 2.8 N.m (25 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ignition Off Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation Ignition Off Draw (IOD) Fuse: Description and Operation Ignition-Off Draw Fuse SYSTEM OPERATION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is removed when the vehicle is shipped from the factory. This fuse feeds various accessories that require battery current when the ignition switch is in the Off position, including the clock. The fuse is removed to prevent battery discharge during vehicle storage. When removing or installing the IOD fuse, it is important that the ignition switch be in the Off position. Failure to place the ignition switch in the Off position can cause the radio display to become scram-bled when the IOD fuse is removed and replaced. Removing and replacing the IOD fuse again, with the ignition switch in the Off position, will correct the scrambled display condition. The IOD fuse should be checked if the radio or clock displays are inoperative. The IOD fuse is located in the junction block. Refer to the label on the back of the junction block fuse access panel for IOD fuse identification and location. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Power Distribution Center, Battery, Windshield Washer Reservoir Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations Power Distribution Center, Battery, Windshield Washer Reservoir Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation Ignition Off Draw (IOD) Fuse: Description and Operation Ignition-Off Draw Fuse SYSTEM OPERATION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is removed when the vehicle is shipped from the factory. This fuse feeds various accessories that require battery current when the ignition switch is in the Off position, including the clock. The fuse is removed to prevent battery discharge during vehicle storage. When removing or installing the IOD fuse, it is important that the ignition switch be in the Off position. Failure to place the ignition switch in the Off position can cause the radio display to become scram-bled when the IOD fuse is removed and replaced. Removing and replacing the IOD fuse again, with the ignition switch in the Off position, will correct the scrambled display condition. The IOD fuse should be checked if the radio or clock displays are inoperative. The IOD fuse is located in the junction block. Refer to the label on the back of the junction block fuse access panel for IOD fuse identification and location. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4914 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4915 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4916 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4917 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4918 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4919 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4920 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4921 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4922 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4923 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4924 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4925 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4926 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4927 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4928 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4929 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4930 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4931 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4932 Auxiliary Power Outlet: Description and Operation SYSTEM OPERATION An accessory power outlet is optional equipment on this model. The power outlet is installed in the instrument panel accessory switch plate, which is located near the center of the instrument panel, inboard of the radio. The power outlet base is secured by a snap fit within the instrument panel accessory switch plate. A plastic protective cap snaps into the power outlet base when the power outlet is not being used. The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the Power Distribution Center (PDC) at all times. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4933 Auxiliary Power Outlet: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the Power Distribution Center (PDC). If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the PDC. If OK, go to Step 4. If not OK, repair the open circuit to the battery as required. 3. Remove the plastic protective cap from the power outlet receptacle. Check for continuity between the inside circumference of the power outlet receptacle and a good ground. There should be continuity. If OK, go to Step 5. If not OK, go to Step 6. 4. Check for battery voltage at the insulated contact located at the back of the power outlet receptacle. If not OK, go to Step 6. 5. Disconnect and isolate the battery negative cable. Remove the instrument panel accessory switch plate. Check for continuity between the ground circuit cavity of the power outlet wire harness connector and a good ground. There should be continuity. If OK, go to Step 7. If not OK, repair the open circuit to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power outlet wire harness connector. If OK, replace the faulty power outlet receptacle. If not OK, repair the open circuit to the PDC fuse as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4934 Auxiliary Power Outlet: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Cigar Lighter And Power Outlet 2. Unsnap the power outlet protective cap from the power outlet receptacle base. Power Outlet Remove/Install - Typical 3. Look inside the power outlet receptacle base and note the position of the rectangular retaining bosses of the mount that secures the receptacle base to the instrument panel accessory switch plate. 4. Insert a pair of external snap ring pliers into the power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of tile mount. 6. Remove the power outlet mount from the instrument panel accessory switch plate. 7. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Description and Operation Circuit Breaker: Description and Operation SYSTEM OPERATION An automatic resetting circuit breaker in the junction block is used to protect the power seat system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck seat adjuster. The circuit breaker cannot be repaired and, if faulty or damaged, it must be replaced. An automatic resetting circuit breaker in the junction block is used to protect the power window system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck window glass or regulator. The circuit breaker cannot be repaired and, if faulty, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Description and Operation > Page 4938 Circuit Breaker: Testing and Inspection 1. Locate the correct circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Description and Operation > Page 4939 Circuit Breaker: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the end cap from the driver side end of the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel End Cap. Junction Block 3. Unplug the circuit breaker from the junction block. 4. Install the circuit breaker by aligning its terminals with the cavities in the junction block and pushing the circuit breaker firmly into place. 5. Connect the battery negative cable. 6. Test the circuit breaker operation. 7. Reinstall the end cap on the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel End Cap. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Description and Operation Electronic Noise Suppressor: Description and Operation SYSTEM OPERATION Radio Frequency Interference (RFI) and ElectroMagnetic Interference (EMI) noise suppression is accomplished primarily through circuitry internal to the radio receivers. These internal suppression devices are only serviced as part of the radio receiver. External suppression devices that are serviced, and should be checked in the case of RFI or EMI noise complaints, include the following: Radio antenna base ground - Radio chassis ground wire, strap, or bracket - Engine-to-body ground strap (if the vehicle is so equipped) - Cab-to-bed ground strap (if the vehicle is so equipped) - Heater core ground strap (if the vehicle is so equipped) - Resistor-type spark plugs - Radio suppression-type secondary ignition wiring. In addition, if the source of RFI or EMI noise is identified as a component on the vehicle (i.e., generator, blower motor, etc.), the ground path for that component should be checked. If excessive resistance is found in that circuit, repair that circuit as required before considering any component replacement. If the source of the noise is identified as two-way mobile radio or telephone equipment, check the equipment installation for the following: Power connections should be made directly to the battery, and fused as closely to the battery as possible. - The antenna should be mounted on the roof or toward the rear of the vehicle. Remember that magnetic antenna mounts on the roof panel can adversely affect the operation of an overhead console compass, if the vehicle is so equipped. - The antenna cable should be fully shielded coaxial cable, should be as short as is practical, and should be routed away from the factory-installed vehicle wire harnesses whenever possible. - The antenna and cable must be carefully matched to ensure a low Standing Wave Ratio (SWR). Fleet vehicles are available with an extra-cost RFI suppressed Powertrain Control Module (PCM). This unit reduces interference generated by the PCM on some radio frequencies used in two-way radio communications. However, this unit will not resolve complaints of RFI in the commercial AM or FM radio frequency ranges Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Power Distribution Center Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Power Distribution Center > Page 4947 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions Multiple Junction Connector: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4952 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4953 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4954 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4955 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4956 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4957 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4958 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4959 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4960 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4961 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4962 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4963 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4964 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4965 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4966 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4967 Multiple Junction Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4968 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4969 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4970 Multiple Junction Connector: Electrical Diagrams 8w-12-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 8w-12-3 Diagrams Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 8w-12-6 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 8w-12-7 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4974 8w-12-8 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4975 8w-12-9 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4976 8w-12-10 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4977 8w-12-11 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4978 8w-12-12 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4979 8w-12-13 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4980 8w-12-14 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4981 8w-12-15 NOTE: To view Diagrams referred to in these diagrams SEE Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Page 4982 Multiple Junction Connector: Service and Repair Junction Block REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the knee blocker from the instrument panel. See Knee Blocker Replacement. 3. Reach through the outboard side of the instrument panel steering column opening to access and unplug all of the wire harness connectors from the junction block cavities. Junction Block Remove/Install 4. With the driver side front door open, remove the two screws that secure the junction block to the left instrument panel end bracket. 5. Reach through the outboard side of the instrument panel steering column opening to remove the junction block from the left instrument panel end bracket. 6. Reverse the removal procedures to install. Tighten the mounting screws to 2.8 N.m (25 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Ignition Off Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation Ignition Off Draw (IOD) Fuse: Description and Operation Ignition-Off Draw Fuse SYSTEM OPERATION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is removed when the vehicle is shipped from the factory. This fuse feeds various accessories that require battery current when the ignition switch is in the Off position, including the clock. The fuse is removed to prevent battery discharge during vehicle storage. When removing or installing the IOD fuse, it is important that the ignition switch be in the Off position. Failure to place the ignition switch in the Off position can cause the radio display to become scram-bled when the IOD fuse is removed and replaced. Removing and replacing the IOD fuse again, with the ignition switch in the Off position, will correct the scrambled display condition. The IOD fuse should be checked if the radio or clock displays are inoperative. The IOD fuse is located in the junction block. Refer to the label on the back of the junction block fuse access panel for IOD fuse identification and location. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Power Distribution Center, Battery, Windshield Washer Reservoir Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations Power Distribution Center, Battery, Windshield Washer Reservoir Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation Ignition Off Draw (IOD) Fuse: Description and Operation Ignition-Off Draw Fuse SYSTEM OPERATION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is removed when the vehicle is shipped from the factory. This fuse feeds various accessories that require battery current when the ignition switch is in the Off position, including the clock. The fuse is removed to prevent battery discharge during vehicle storage. When removing or installing the IOD fuse, it is important that the ignition switch be in the Off position. Failure to place the ignition switch in the Off position can cause the radio display to become scram-bled when the IOD fuse is removed and replaced. Removing and replacing the IOD fuse again, with the ignition switch in the Off position, will correct the scrambled display condition. The IOD fuse should be checked if the radio or clock displays are inoperative. The IOD fuse is located in the junction block. Refer to the label on the back of the junction block fuse access panel for IOD fuse identification and location. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5006 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5007 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5008 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5014 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5015 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5016 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised Alignment: All Technical Service Bulletins Steering Wander - Diagnosis and Correction Revised NUMBER: 19-07-00 GROUP: Steering DATE: September 22, 2000 SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering wander. MODELS: 1998-2001 (AB) Ram Van/Wagon SYMPTOM/CONDITION: Steering Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering wander can be created by a number of different conditions including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying extra added weight (e.g. tool boxes). ^ Steering and/or suspension components that are worn or damaged. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: UNDER CERTAIN ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. DIAGNOSIS: 1. Verify that the vehicle is not equipped with non-factory installed options or equipment that may cause the vehicle to wander such as heavy toolboxes or hardware that may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended may cause the vehicle to wander and should be replaced before continuing with the diagnosis. 3. Inflate all tires to the pressure specified in the Tire Inflation Pressure sheet (located in the glove box). NOTE: TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS BUT, ONLY IF THE VEHICLE IS AT CURB OR LIGHT LOAD CONDITIONS. 4. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without cross wind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Proceed to the next step if the vehicle exhibits a steering wander condition. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-3 OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, ETC.). 5. Raise the vehicle on an appropriate lift. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised > Page 5021 6. Secure a dial indicator to the lower control arm. Position the dial indicator so that the tip of the indicator contacts the inside face of the rotor (Figure 1). 7. Place your hands at the top and bottom of the tire/wheel assembly and push the tire/wheel assembly inboard (Figure 2). Zero the dial indicator. With your hands at the top and bottom of the tire/wheel assembly, pull the tire/wheel assembly outboard (Figure 3). Record the dial indicator reading. Perform this procedure on both front wheel bearings and proceed to the next step if the wheel bearing endplay exceeds 0.025 - 0.076 mm (0.001 - 0.003 in.). Proceed to Step 9 if wheel-bearing endplay on both front wheel bearings are within specifications. NOTE: WHEEL BEARING INSPECTION AND ADJUSTMENT IS ONLY REQUIRED ON WHEEL BEARINGS EXCEEDING 0.025 - 0.076 MM (0.001 - 0.003 IN.) ENDPLAY. 8. Remove the wheel bearing protective end cap, cotter pin, nut lock, nut, and washer from the spindle. Inspect the wheel bearings. If it is determined that wheel bearing replacement is necessary, refer to the appropriate Ram Van/Wagon Service Manual, Group 02, Wheel Bearings, for removal and installation information. Reinstall the wheel bearings, washer, and adjustment nut if the wheel bearings pass the inspection. 9. Using a torque wrench, tighten the wheel bearing adjustment nut to 54 N.m (40 ft. lbs.) while rotating the tire/wheel assembly. Stop the wheel from rotating and loosen the nut. Using the procedure identified in Steps 6 and 7 to measure endplay, adjust the front wheel bearing endplay until 0.025 - 0.076 mm (0.001 - 0.003 in.) endplay has been achieved. Install the nut lock and a new cotter pin. 10. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual. Any worn steering and/or suspension component must be replaced prior to performing an alignment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised > Page 5022 11. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the chart for proper alignment specifications. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised Alignment: All Technical Service Bulletins Steering Wander - Diagnosis and Correction Revised NUMBER: 19-07-00 GROUP: Steering DATE: September 22, 2000 SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering wander. MODELS: 1998-2001 (AB) Ram Van/Wagon SYMPTOM/CONDITION: Steering Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering wander can be created by a number of different conditions including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying extra added weight (e.g. tool boxes). ^ Steering and/or suspension components that are worn or damaged. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: UNDER CERTAIN ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. DIAGNOSIS: 1. Verify that the vehicle is not equipped with non-factory installed options or equipment that may cause the vehicle to wander such as heavy toolboxes or hardware that may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended may cause the vehicle to wander and should be replaced before continuing with the diagnosis. 3. Inflate all tires to the pressure specified in the Tire Inflation Pressure sheet (located in the glove box). NOTE: TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS BUT, ONLY IF THE VEHICLE IS AT CURB OR LIGHT LOAD CONDITIONS. 4. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without cross wind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Proceed to the next step if the vehicle exhibits a steering wander condition. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-3 OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, ETC.). 5. Raise the vehicle on an appropriate lift. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised > Page 5028 6. Secure a dial indicator to the lower control arm. Position the dial indicator so that the tip of the indicator contacts the inside face of the rotor (Figure 1). 7. Place your hands at the top and bottom of the tire/wheel assembly and push the tire/wheel assembly inboard (Figure 2). Zero the dial indicator. With your hands at the top and bottom of the tire/wheel assembly, pull the tire/wheel assembly outboard (Figure 3). Record the dial indicator reading. Perform this procedure on both front wheel bearings and proceed to the next step if the wheel bearing endplay exceeds 0.025 - 0.076 mm (0.001 - 0.003 in.). Proceed to Step 9 if wheel-bearing endplay on both front wheel bearings are within specifications. NOTE: WHEEL BEARING INSPECTION AND ADJUSTMENT IS ONLY REQUIRED ON WHEEL BEARINGS EXCEEDING 0.025 - 0.076 MM (0.001 - 0.003 IN.) ENDPLAY. 8. Remove the wheel bearing protective end cap, cotter pin, nut lock, nut, and washer from the spindle. Inspect the wheel bearings. If it is determined that wheel bearing replacement is necessary, refer to the appropriate Ram Van/Wagon Service Manual, Group 02, Wheel Bearings, for removal and installation information. Reinstall the wheel bearings, washer, and adjustment nut if the wheel bearings pass the inspection. 9. Using a torque wrench, tighten the wheel bearing adjustment nut to 54 N.m (40 ft. lbs.) while rotating the tire/wheel assembly. Stop the wheel from rotating and loosen the nut. Using the procedure identified in Steps 6 and 7 to measure endplay, adjust the front wheel bearing endplay until 0.025 - 0.076 mm (0.001 - 0.003 in.) endplay has been achieved. Install the nut lock and a new cotter pin. 10. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual. Any worn steering and/or suspension component must be replaced prior to performing an alignment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised > Page 5029 11. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the chart for proper alignment specifications. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5030 Alignment: By Symptom Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5031 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5032 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5033 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5034 ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5035 THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5036 CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5037 This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5038 TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5039 The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5040 NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 5041 Alignment: Specifications CASTER: Preferred .............................................................................................................................................. ...................................................................... +2.5° Range ................................................................. ..................................................................................................................................................... ± 1.50° Maximum Right/Left Difference .................................................................................................. ............................................................................. 1.25° CAMBER: Preferred .............................................................................................................................................. ........................................................................... 0° Range ................................................................. ....................................................................................................................................................... ± 0.6° Maximum Right/Left Difference .................................................................................................... ................................................................................ 0° TOTAL TOE-IN: Preferred .............................................................................................................................................. ........................................................................... 0° Range ................................................................. ..................................................................................................................................................... ± 0.25° Maximum Right/Left Difference .................................................................................................. ............................................................................. 0.05° THRUST ANGLE Preferred .............................................................................................................................................. ........................................................................... 0° Range ................................................................. ....................................................................................................................................................... ± 0.4° Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 5042 Alignment: Description and Operation GENERAL INFORMATION Wheel Alignment Measurements Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. Caster - is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides negative caster. Tilting the top of the knuckle rearward provides positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns. Camber - is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire. Toe - is the difference between the leading inside edges and trailing inside edges of the front tires. Uneven wheel toe position cause's unstable steering, uneven tire near and steering wheel off-center. The wheel toe position is the final front wheel alignment adjustment. Thrust Angle - is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 5043 Alignment: Testing and Inspection PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear or adjustment. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 5044 Alignment: Service and Repair GENERAL INFORMATION The front wheel alignment angles should be set to preferred specifications. This will prevent abnormal tire tread wear. Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down several times. Always release the bumper in the down position. CAMBER AND CASTER Camber and caster angle adjustments involve repositioning the upper suspension arm pivot bar. Alignment adjustments are accomplished by changing the position of the pivot bar. Adjuster Tool 8199, or equivalent is used to adjust the camber and caster angles. Tools Attached To Frame 1. Clamp the tool on the upper suspension arm frame bracket. Use the two clamp bolts to attach the tool to the bracket. 2. With the adjustment tools installed, loosen both upper suspension arm bolts completely. 3. Tighten or loosen the tool adjustment bolts to move the upper suspension arm inward or outward to obtain the proper camber and caster angles. Caster: Move the rear position of the pivot bar in or out. This will change the caster angle significantly and camber angle only slightly. To retain the camber while adjusting caster, move the rear pivot bar in or out. Move the forward pivot very slightly in the opposite direction. NOTE: For example, to increase a positive caster angle move the rear position of the pivot bar inward. Move the front of pivot bar outward until the original camber angle is obtained. Camber: Move the forward position of the pivot bar in or out. This will change the camber angle significantly and caster angle only slightly. The camber angle should be adjusted to the service specifications. Tighten the pivot bar bolts to 298 Nm (220 ft. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 5045 TOE POSITION The wheel toe position is the final adjustment procedure. 1. Secure the steering wheel with the front wheels in the straight ahead position. For power steering vehicles, start the engine before straightening the wheels. 2. Loosen the tie rod adjustment sleeve clamp bolts. 3. Adjust the wheel toe position by rotating the tie rod adjustment sleeve. 4. Position the adjustment sleeve clamps so the ends are not located at the sleeve slot. Tighten the tie rod sleeve clamps to: - Standard Duty: 23 Nm (17 ft. lbs.) - Heavy Duty: 35 Nm (26 ft. lbs.) Ensure the clamp bolts are located at the underside of the sleeve. 5. Verify camber, caster and toe position. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 5046 Adjuster, Caster & Camber 8119 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications Center Link: Specifications To Idler Arm Nut .................................................................................................................................. .................................................... 64 Nm (47 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation The steering knuckles are used to steer the vehicle. The knuckles are mounted to the ball studs at the end of the suspension arms. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation > Page 5054 Front Steering Knuckle: Service and Repair REMOVAL 1. Raise and support the vehicle. Place a jack under outer end of lower suspension arm. 2. Remove wheel and tire assembly. 3. Remove disc brake caliper and rotor. 4. Remove tie rod from steering knuckle arm. 5. Remove cotter pins and nuts from upper and lower ball joints. 6. Use Ball Stud Remover C-3564-A, or equivalent to free upper and lower ball joints from steering knuckle. 7. Remove tool and steering knuckle assembly. 8. Remove the rotor dust shield and steering arm from steering knuckle. INSTALLATION 1. Install brake rotor dust shield on steering knuckle and tighten bolts to 24 Nm (18 ft. lbs.). 2. Install steering arm on knuckle and tighten nuts to; - LD 5/8-18 nut: 294 Nm (217 ft. lbs.) - HD 3/4-16 nut: 330 Nm (225 ft. lbs.) 3. Position steering knuckle on upper and lower ball joints and install nuts. Tighten upper nut to 183 Nm (135 ft. lbs). Install new cotter pins. 4. Tighten the lower nut to: - LD 11/16-16 nut: 183 Nm (135 ft. lbs.) - HD 3/4-16 nut: 237 Nm (175 ft. lbs.) 5. Install tie rod to steering knuckle arm. 6. Install rotor and disc brake caliper. 7. Install wheel and tire assembly and lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Technical Service Bulletins > Customer Interest for Idler Arm: > 02-08-98 > Aug > 98 > Front Suspension - Knocking Noise on Turns Idler Arm: Customer Interest Front Suspension - Knocking Noise on Turns NO: 02-08-98 GROUP: Suspension DATE: Aug. 21, 1998 SUBJECT: Knocking Noise In The Front Suspension When The Steering Wheel Is Rotated To The Full Left/Right MODELS: 1998 - 1999 (AB) Ram Van NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT ON MAY 20, 1998 (MDH 0520XX) THROUGH AUGUST 03, 1998 (MDH 0803XX). SYMPTOM/CONDITION: A knocking noise may be heard in the front suspension when the steering wheel is rotated to the full left or right steering positions. The noise may be more prevalent when the steering wheel is rotated to the full right or left positions with the vehicle moving over bumps in the road. DIAGNOSIS: With the vehicle sitting at curb height and the vehicle weight resting on the tires of the vehicle, rotate the steering wheel to a full left or right lock turn. Inspect the position of the idler arm relative to the front stabilizer bar. If there is an interference condition between the idler arm and the stabilizer bar, perform the Repair Procedure. PARTS REQUIRED: 1 52039336AC Bar, Stabilizer REPAIR PROCEDURE: This bulletin involves installing a revised stabilizer bar. 1. Raise and support the vehicle. 2. Remove the stabilizer bar link bolt nuts, retainers, and insulators from the strut bar (Figure 1). 3. Remove the stabilizer bar link bolts, retainers, insulators, and spacers from the stabilizer bar. 4. Remove the stabilizer bar retaining bolts and remove the stabilizer bar. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Technical Service Bulletins > Customer Interest for Idler Arm: > 02-08-98 > Aug > 98 > Front Suspension - Knocking Noise on Turns > Page 5063 5. Remove the bushings from the stabilizer bar. 6. Install the bushings onto the new stabilizer bar p/n 52039336AC. 7. Position the new stabilizer bar p/n 52039336AC onto the frame rails. NOTE: ENSURE THE STABILIZER BAR IS CENTERED WITH EQUAL SPACING ON BOTH SIDES. 8. Install stabilizer retainers and bolts. Tighten the bolts to 23 Nm (200 in. lbs.). 9. Install the link bolts, retainers, spacers, and insulators onto the stabilizer bar and onto the strut bar. 10. Install the link bolt nuts. Tighten the nuts to 11 N.m (100 in. lbs.). 11. Remove the support and lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-20-01-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Arm: > 02-08-98 > Aug > 98 > Front Suspension - Knocking Noise on Turns Idler Arm: All Technical Service Bulletins Front Suspension - Knocking Noise on Turns NO: 02-08-98 GROUP: Suspension DATE: Aug. 21, 1998 SUBJECT: Knocking Noise In The Front Suspension When The Steering Wheel Is Rotated To The Full Left/Right MODELS: 1998 - 1999 (AB) Ram Van NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT ON MAY 20, 1998 (MDH 0520XX) THROUGH AUGUST 03, 1998 (MDH 0803XX). SYMPTOM/CONDITION: A knocking noise may be heard in the front suspension when the steering wheel is rotated to the full left or right steering positions. The noise may be more prevalent when the steering wheel is rotated to the full right or left positions with the vehicle moving over bumps in the road. DIAGNOSIS: With the vehicle sitting at curb height and the vehicle weight resting on the tires of the vehicle, rotate the steering wheel to a full left or right lock turn. Inspect the position of the idler arm relative to the front stabilizer bar. If there is an interference condition between the idler arm and the stabilizer bar, perform the Repair Procedure. PARTS REQUIRED: 1 52039336AC Bar, Stabilizer REPAIR PROCEDURE: This bulletin involves installing a revised stabilizer bar. 1. Raise and support the vehicle. 2. Remove the stabilizer bar link bolt nuts, retainers, and insulators from the strut bar (Figure 1). 3. Remove the stabilizer bar link bolts, retainers, insulators, and spacers from the stabilizer bar. 4. Remove the stabilizer bar retaining bolts and remove the stabilizer bar. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Arm: > 02-08-98 > Aug > 98 > Front Suspension - Knocking Noise on Turns > Page 5069 5. Remove the bushings from the stabilizer bar. 6. Install the bushings onto the new stabilizer bar p/n 52039336AC. 7. Position the new stabilizer bar p/n 52039336AC onto the frame rails. NOTE: ENSURE THE STABILIZER BAR IS CENTERED WITH EQUAL SPACING ON BOTH SIDES. 8. Install stabilizer retainers and bolts. Tighten the bolts to 23 Nm (200 in. lbs.). 9. Install the link bolts, retainers, spacers, and insulators onto the stabilizer bar and onto the strut bar. 10. Install the link bolt nuts. Tighten the nuts to 11 N.m (100 in. lbs.). 11. Remove the support and lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-20-01-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Technical Service Bulletins > Page 5070 Idler Arm: Specifications Mounting Bolts ..................................................................................................................................... ................................................ 155 Nm (115 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5076 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5077 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5078 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Capacity ............................................................................................................................................... ....................................................... 1.28 L (2.7 pints) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 5081 Power Steering Fluid: Fluid Type Specifications The recommended lubricant is Mopar Power Steering Fluid. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications Power Steering Fluid Cooler: Specifications To Block Bolts ...................................................................................................................................... .................................................... 41 Nm (30 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications Power Steering Fluid Reservoir: Specifications Attaching Bolts ..................................................................................................................................... .................................................... 48 Nm (35 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure Line ...................................................................................................................................... ...................................................... 35 Nm (25 ft. lbs.) Return Line ..................................................... .......................................................................................................................................... 35 Nm (25 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Pump: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5095 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5096 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5097 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Bracket Bolts ....................................................................................................................................... ..................................................... 28 Nm (21 ft. lbs.) Pump Bolts ....................................................... ........................................................................................................................................ 54 Nm (40 ft. lbs.) Flow Control Valve ....................................................................................................................... ........................................................... 75 Nm (55 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 5100 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Relief Pressure ± 50 ............................................................................................................................ ................................................... 9653 kPa (1400 psi) Flow Rate At 1500 RPM ................................. ................................................................................................................................................ 2.4 2.8 GPM Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5101 Power Steering Pump: Description and Operation The P-Series pump is used on these vehicles. Hydraulic pressure is provided for the power steering gear by the belt driven power steering pump. The power steering pump is a constant flow rate and displacement, vane-type pump. The pump is connected to the steering gear via the pressure hose and the return hose. The pump shaft has a pressed-on pulley that is belt driven by the crankshaft pulley. Trailer tow option vehicles are equipped with a power steering pump oil cooler. The oil cooler is mounted to the radiator support. NOTE: Power steering pumps are not interchangeable with pumps installed on other vehicles. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5102 Power Steering Pump: Testing and Inspection Pump Leakage Refer to illustration for areas to inspect for leakage. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation Power Steering Pump: Service and Repair Power Steering Pump Initial Operation WARNING: The fluid level should be checked with engine off to prevent injury from moving components. CAUTION: Use Mopar (R) Power Steering Fluid or equivalent. Do not use automatic transmission fluid and do not overfill. Wipe filler cap clean, then check the fluid level. The dipstick should indicate COLD when the fluid is at normal temperature. 1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 2. Start the engine and let run for a few seconds then turn engine off. 3. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 4. Raise the front wheels off the ground. 5. Slowly turn the steering wheel right and left, lightly contacting the wheel stops at least 20 times. 6. Check the fluid level add if necessary. 7. Lower the vehicle, start the engine and turn the steering wheel slowly from lock to lock. 8. Stop the engine and check the fluid level and refill as required. 9. If the fluid is extremely foamy or milky looking, allow the vehicle to stand a few minutes and repeat the procedure. CAUTION: Do not run a vehicle with foamy fluid for an extended period. This may cause pump damage. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation > Page 5105 Power Steering Pump: Service and Repair Power Steering Pump Pulley Replacement REMOVAL 1. Remove pump assembly. 2. Remove pulley from pump with Puller C-4333, or equivalent. INSTALLATION 1. Replace pulley if bent, cracked, or loose. 2. Install pulley on pump with Installer C-4063-B, or equivalent flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft. 3. Install pump assembly. 4. With Serpentine Belts; Run engine until warm (5 min.) and note any belt chirp. If chirp exists, move pulley outward approximately 0.5 mm (0.020 inch). If noise increases, press on 1.0 mm (0.040 inch). Be careful that pulley does not contact mounting bolts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation > Page 5106 Power Steering Pump: Service and Repair Power Steering Pump Removal and Installation WARNING: Do not attempt to remove the pump without removing the belt first. the automatic tensioner is under a high spring load. REMOVAL 1. Remove drive belt by rotating tensioner clockwise and sliding belt off tensioner pulley. 2. Disconnect hoses from the power steering pump and cap fittings. 3. Remove bracket bolts and remove pump assembly. 4. Remove the pump pulley. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation > Page 5107 5. Remove pump attaching screws. INSTALLATION 1. Install pump bracket to pump and tighten the bolts to 28 Nm (21 ft. lbs.). 2. Install the pump pulley. 3. Install pump assembly on engine block and tighten bolts to 41 Nm (30 ft. lbs.). 4. Connect hoses to pump and tighten fitting to 35 Nm (25 ft. lbs.). 5. Install serpentine belt. 6. Fill pump reservoir with power steering fluid only, and perform Pump Initial Operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Arm > Component Information > Specifications Steering Arm: Specifications LD 5/8 Bolt ........................................................................................................................................... ................................................ 294 Nm (217 ft. lbs.) HD 3/4 Bolt ........................................................ .................................................................................................................................. 330 Nm (225 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: The airbag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the airbag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the airbag and possible personal injury. The fasteners, screws, and bolts, originally used for the airbag components, have special coatings and are specifically designed for the airbag system. They must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books . Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 5115 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair Steering Column Cover: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, move the tilt steering column to the fully raised position. 3. Remove the end cap from the left end of the instrument panel. See Instrument Panel End Cap Replacement. Steering Column Opening Cover Remove/Install 4. Remove the three screws that secure the lower edge of the steering column opening cover to the knee blocker. 5. Remove the two screws that secure the out board end of the steering column opening cover to the left instrument panel end bracket. 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper edge of the steering column opening cover away from the instrument panel just below the cluster bezel to release the four snap clip retainers that secure the cover to the instrument panel. 7. Remove the steering column opening cover from the instrument panel. 8. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest for Steering Gear: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest for Steering Gear: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5127 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest for Steering Gear: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5128 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest for Steering Gear: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5129 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-002-01A > Sep > 01 > Steering/Suspension Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-002-01A > Sep > 01 > Steering/Suspension Wander Diagnosis/Repair > Page 5135 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-002-01A > Sep > 01 > Steering/Suspension Wander Diagnosis/Repair > Page 5136 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-002-01A > Sep > 01 > Steering/Suspension Wander Diagnosis/Repair > Page 5137 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 5138 Steering Gear: Specifications GEAR CODE & RATIO: HF ........................................................................................................................................................ ................................................................ 16 - 13:1 WORM-SHAFT BEARING: Preload ................................................................................................................................................ .......................... 0.45 - 1.13 Nm (10 - 15 inch lbs.) PITMAN SHAFT OVERCENTER DRAG: New (Under 400 Miles) .................................................................................................................................. 0.45 - 0.90 Nm (6 - 10 inch lbs.) + preload Used (Over 400 Miles) ......................................................................................................................................... 0.5 - 0.6 Nm (4 - 5 inch lbs.) + preload TIGHTENING TORQUES: Adjustment Cap Locknut ..................................................................................................................... ............................................... 108 Nm (80 ft. lbs.) Adjustment Screw Locknut .................................. ................................................................................................................................. 27 Nm (20 ft. lbs.) Gear To Bracket Bolts ................................................................................................................. ..................................................... 142 Nm (105 ft. lbs.) Bracket To Frame Bolts ............................... ..................................................................................................................................... 136 Nm (100 ft. lbs.) Pitman Shaft Nut ...................................................................................................................... ......................................................... 251 Nm (185 ft. lbs.) Rack Piston Plug ...................................... ........................................................................................................................................... 102 Nm (75 ft. lbs.) Side Cover Bolts ................................................................................................................ ................................................................... 61 Nm (45 ft. lbs.) Return Guide Clamp Bolts ................. ................................................................................................................................................. 5 Nm (48 inch lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 5139 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 5140 Steering Gear: Description and Operation The power steering gear is a recirculating ball type gear. The gear acts as a rolling thread between the worm shaft and rack piston. The worm shaft is supported by a thrust bearing at the lower end and a bearing assembly at the upper end. When the worm shaft is turned the rack piston moves. The rack piston teeth mesh with the pitman shaft. Turning the worm shaft turns the pitman shaft, which turns the steering linkage. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 5141 Steering Gear: Testing and Inspection Refer to illustrations for areas to inspect for leakage. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments > Worm Thrust Bearing Steering Gear: Adjustments Worm Thrust Bearing CAUTION: Steering gear must be adjusted in the proper order. If adjustments are not performed in order, gear damage and improper steering response may result. NOTE: Adjusting the steering gear in the vehicle is not recommended. Remove gear from the vehicle and drain the fluid. Then mount gear in a vise to perform adjustments. 1. Mount the gear carefully into a vise. CAUTION: Do not overtighten the vise on the gear case. This may affect the adjustment. 2. Remove adjuster plug locknut. 3. Rotate the stub shaft back and forth with a 12 point socket to drain the remaining fluid. 4. Turn the adjuster in with Spanner Wrench C-4381, or equivalent. Tighten the plug and thrust bearing in the housing until firmly bottomed in housing about 34 Nm (25 ft. lbs.). 5. Place an index mark on the housing even with one of the holes in adjuster plug. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments > Worm Thrust Bearing > Page 5144 6. Measure back (counterclockwise) 5.08 mm (0.20 inch) and mark housing. 7. Rotate adjustment cap back (counterclockwise) with spanner wrench until hole is aligned with the second mark. 8. Install and tighten locknut to 108 Nm (80 ft. lbs.). Be sure adjustment cap does not turn while tightening the locknut. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments > Worm Thrust Bearing > Page 5145 Steering Gear: Adjustments Sector Shaft Over Center NOTE: Before performing this procedure, the worm bearing preload adjustment must be preformed. 1. Rotate the stub shaft with a 12 point socket from stop to stop and count the number of turns. 2. Starting at either stop turn the stub shaft back 1/2 the total number of turns. This is the center of the gear travel. 3. Place the torque wrench in the vertical position on the stub shaft. Rotate the wrench 45 degrees each side of the center and record the highest rotational torque in this range. This is the Over-Center Rotating Torque. NOTE: The stub shaft must rotate smoothly without sticking or binding. 4. Rotate the stud shaft between 90° and 180° to the left of center and record the left off-center preload. Repeat this to the right of center and record the right off-center preload. The average of these two recorded readings is the Preload Rotating Torque. 5. The Over-Center Rotating Torque should be 0.45 - 0.9 Nm (4 - 8 inch lbs.) higher than the Preload Rotating Torque. 6. If an adjustment to the Over-Center Rotating Torque is necessary, first loosen the adjuster lock nut. Then turn the pitman shaft adjuster screw back (Counterclockwise) until fully extended, then turn back in (Clockwise) one full turn. 7. Remeasure Over-Center Rotating Torque. If necessary turn the adjuster screw and repeat measurement until correct Over-Center Rotating Torque is reached. NOTE: To increase the preload turn the screw CLOCKWISE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments > Worm Thrust Bearing > Page 5146 8. Prevent the adjuster screw from turning while tightening adjuster lock nut. Tighten the adjuster lock nut to 49 Nm (36 ft. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement Steering Gear: Service and Repair Steering Gear Replacement REMOVAL 1. Position the front wheels straight-ahead. 2. Raise and support the vehicle. 3. Remove and cap fluid hoses from steering gear. 4. Remove the coupler retaining bolt and slide the coupler off the steering gear stub shaft. 5. Mark the pitman shaft and pitman arm for installation reference. Remove the pitman arm from the shaft with Puller C-4150A, or equivalent. 6. Remove the steering gear bracket retaining bolts and nuts. 7. Remove the steering gear and bracket from the vehicle. 8. Remove the gear from the mounting bracket. INSTALLATION 1. Position steering gear mounting bracket on the gear. Install mounting bolts and tighten to 142 Nm (105 ft. lbs.). 2. Position the steering gear and bracket on the frame rail. Install the bolts and nuts. Tighten bolts and nuts to 136 Nm (100 ft. lbs.). 3. Align the coupler shaft index marks to the steering gear and steering shaft. 4. Install the steering coupler and install new bolts. Tighten bolts to 49 Nm (36 ft. lbs.). 5. Align and install the pitman arm. 6. Install the washer and retaining nut on the pitman shaft. Tighten the nut to 251 Nm (185 ft. lbs.). 7. Connect fluid hoses to steering gear. Tighten hose fittings to 28 Nm (21 ft. lbs.). 8. Remove support and lower vehicle. 9. Add fluid, perform Power Steering Pump/Service and Repair/Initial Operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5149 Steering Gear: Service and Repair Overhaul Housing End Plug DISASSEMBLY 1. Unseat and remove retaining ring from groove with a punch through the hole in the end of the housing. 2. Rotate stub shaft slowly COUNTER-CLOCKWISE to force the end plug out from housing. CAUTION: Do not turn stub shaft any further than necessary. The rack piston balls will drop out of the rack piston circuit if the stub shaft is turned too far. 3. Remove O-ring seal. ASSEMBLY 1. Lubricate O-ring with power steering fluid. 2. Install into the housing. 3. Install plug, tap lightly with a plastic mallet to seat it. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5150 4. Install retaining ring with open end 25 mm (1 inch) from access hole. 5. Adjust pitman arm shaft, refer to Adjustments/Over-Center Rotational Torque. Pitman Shaft/Seals/Bearing DISASSEMBLY 1. Clean exposed end of pitman shaft and housing with a wire brush. 2. Remove preload adjuster nut. 3. Rotate stub shaft with a 12 point socket from stop to stop and count the number of turns. 4. Center the stub shaft by rotating it from the stop 1/2 of the total amount of turns. 5. Remove side cover bolts and remove side cover, gasket and pitman shaft as an assembly. NOTE: The pitman shaft will not clear the housing if it is not centered. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5151 6. Remove pitman shaft from the side cover. 7. Remove dust seal from the housing with a seal pick. CAUTION: Use care not to score the housing bore when prying out seals and washer. 8. Remove retaining ring with snap ring pliers. 9. Remove washer from the housing. 10. Remove oil seal from the housing with a seal pick. 11. Remove pitman shaft bearing from housing with a bearing driver and handle. ASSEMBLY 1. Install pitman shaft bearing into housing with a bearing driver and handle. 2. Coat the oil seals and washer with grease. 3. Install the oil seal with a driver and handle. 4. Install backup washer. 5. Install the retainer ring with snap ring pliers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5152 6. Install dust seal with a driver and handle. 7. Install pitman shaft to side cover by screwing shaft in until it fully seats to side cover. 8. Install preload adjuster nut. Do not tighten nut until after Over-Center Rotation Torque adjustment has been made. 9. Install gasket to side cover and bend tabs around edges of side cover. 10. Install pitman shaft assembly and side cover to housing. 11. Install side cover bolts and tighten to 60 Nm (44 ft. lbs.). 12. Adjust Over-Center Rotation Torque. Refer to Adjustments. Spool Valve DISASSEMBLY 1. Remove lock nut. 2. Remove adjuster nut with Spanner Wrench C-4381, or equivalent. 3. Remove thrust support assembly out of the housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5153 4. Pull stub shaft and valve assembly from the housing. 5. Remove stub shaft from valve assembly by lightly tapping on a block of wood to loosen shaft. Then disengage stub shaft pin from hole in spool valve and separate the valve assembly from stub shaft. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5154 6. Remove spool valve from valve body by pulling and rotating the spool valve from the valve body. 7. Remove spool valve O-ring and valve body teflon and O-rings underneath the teflon rings. 8. Remove the O-ring between the worm shaft and the stub shaft. ASSEMBLY NOTE: Clean and dry all components, then lubricate with power steering fluid. 1. Install spool valve spool O-ring. 2. Install spool valve in valve body by pushing and rotating. Hole in spool valve for stub shaft pin must be accessible from opposite end of valve body. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5155 3. Install stub shaft in valve spool and engage locating pin on stub shaft into spool valve hole. NOTE: Notch in stub shaft cap must fully engage valve body pin and seat against valve body shoulder. 4. Install O-rings and teflon rings over the O-rings on valve body. 5. Install O-ring into the back of the stub shaft. 6. Install stub shaft and valve assembly in the housing. Line up worm shaft to slots in the valve assembly. 7. Install thrust support assembly. NOTE: The thrust support is serviced as an assembly. If any component of the thrust support is damaged the assembly must be replaced. 8. Install adjuster nut and lock nut. 9. Adjust Thrust Bearing Preload and Over-Center Rotating Torque. Rack Piston and Worm Shaft DISASSEMBLY 1. Remove side cover and pitman shaft. 2. Remove housing end plug. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5156 3. Remove rack piston plug. 4. Turn stub shaft COUNTERCLOCKWISE until the rack piston begins to come out of the housing. 5. Insert Arbor C-4175, or equivalent into bore of rack piston and hold tool tightly against worm shaft. 6. Turn the stub shaft COUNTERCLOCKWISE, this will force the rack piston onto the tool and hold the rack piston balls in place. 7. Remove the rack piston and tool together from housing. 8. Remove tool from rack piston. 9. Remove rack piston balls. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5157 10. Remove clamp bolts, clamp and ball guide. 11. Remove teflon ring and O-ring from the rack piston. 12. Remove the adjuster lock nut and adjuster nut. 13. Pull the stub shaft with the spool valve and thrust support assembly out of the housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5158 14. Remove the worm shaft from the housing. ASSEMBLY NOTE: Clean and dry all components and lubricate with power steering fluid. 1. Check for scores, nicks or burrs on the rack piston finished. Slight wear is normal on the worm gear surfaces. 2. Install O-ring and teflon ring on the rack piston. 3. Install worm shaft in the rack piston and align worm shaft spiral groove with rack piston ball guide hole. CAUTION: The rack piston balls must be installed alternately into the rack piston and ball guide. This maintains worm shaft preload. There are 12 black balls and 12 silver (Chrome) balls. The black balls are smaller than the silver balls. 4. Lubricate and install rack piston balls through return guide hole while turning worm shaft COUNTERCLOCKWISE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5159 5. Install remaining balls in guide using grease to hold the balls in place. 6. Install the guide onto rack piston and install clamp and clamp bolts. Tighten bolts to 58 Nm (43 ft. lbs.). 7. Insert Arbor C-4175, or equivalent into bore of rack piston and hold tool tightly against worm shaft. 8. Turn the worm shaft COUNTERCLOCKWISE while pushing on the arbor. This will force the rack piston onto the arbor and hold the rack piston balls in place. 9. Install the races and thrust bearing on the worm shaft and install shaft in the housing. 10. Install the stub shaft with spool valve, thrust support assembly and adjuster nut in the housing. 11. Install the rack piston and arbor tool into the housing. 12. Hold arbor tightly against worm shaft and turn stub shaft CLOCKWISE until rack piston is seated on worm shaft. 13. Install pitman shaft and side cover in the housing. 14. Install rack piston plug and tighten to 150 Nm (111 ft. lbs.). 15. Install housing end plug. 16. Adjust worm shaft thrust bearing preload and over-center rotating torque. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications Retaining Nut ....................................................................................................................................... ..................................................... 47 Nm (35 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications LD Clamp Nut ...................................................................................................................................... ............................................... 22 Nm (200 inch lbs.) HD Clamp Nut .................................................. ........................................................................................................................................ 35 Nm (26 ft. lbs.) LD 9/16 Ball Stud Nut .................................................................................................................. ............................................................ 75 Nm (55 ft. lbs.) HD 5/8 Ball Stud Nut ................................. ............................................................................................................................................ 102 Nm (75 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 5167 Tie Rod End: Service and Repair NOTE: Only the outer tie-rod end can be removed from heavy duty tie rods. REMOVAL 1. Raise and support the vehicle. 2. Remove cotter pin and retaining nut from the tie-rod end ball stud. 3. Remove tie-rod end at the steering knuckle or center link with Puller C-3894-A, or equivalent. 4. Loosen tie-rod sleeve clamp bolts and unthread the tie-rod end from the sleeve. INSTALLATION 1. Thread the tie-rod end into sleeve. 2. Install tie-rod end on steering knuckle arm or enter link. 3. Install nut and tighten to: - 9/16-18 ball stud: 75 Nm (55 ft. lbs.) - 5/8-18 (HD) ball stud: 102 Nm (75 ft. lbs.) 4. Install a new cotter pin. 5. Remove supports and lower vehicle. 6. Adjust the wheel toe position, refer to Alignment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Lower Ball Joint Ball Joint: Specifications Lower Ball Joint LD 11/16 Nut ....................................................................................................................................... ................................................. 183 Nm (135 ft. lbs.) HD 3/4 Nut ....................................................... .................................................................................................................................... 237 Nm (175 ft. lbs.) Joint To Suspension Arm ............................................................................................................. ......................................................... 170 Nm (125 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Lower Ball Joint > Page 5173 Ball Joint: Specifications Upper Ball Joint Ball Joint Nut ....................................................................................................................................... ................................................. 183 Nm (135 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint Ball Joint: Testing and Inspection Lower Ball Joint 1. Raise the front of the vehicle. Install safety floor stands under both lower suspension arms as far outboard as possible. Lower the vehicle onto the stands to support some of all of the vehicle weight. NOTE: The upper suspension arms must not contact the rebound bumpers. 2. Install a dial indicator and clamp assembly to the lower suspension arm. 3. Position indicator plunger against knuckle arm and zero indicator. 4. Raise and lower the wheel with a pry bar under the center of the tire. Measure the axial movement of the knuckle with respect to the suspension arm. 5. If the travel of the suspension arm is 0.51 mm (0.020 inch) or more, replace the ball joint. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint > Page 5176 Ball Joint: Testing and Inspection Upper Ball Joint 1. Position a floor jack under the lower suspension arm. Raise the wheel and allow the tire to lightly contact the floor (vehicle weight relieved from the tire). 2. Mount a dial indicator on the upper suspension arm. Position the indicator plunger against the upper ball stud boss of the steering knuckle. 3. Grasp the top of the tire and apply force in and out. Look for movement at the ball joint between the upper suspension arm and steering knuckle. 4. If lateral movement is greater than 0.8 mm (0.030 inch), replace the ball joint. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement Ball Joint: Service and Repair Lower Ball Joint Replacement REMOVAL 1. Raise and support the vehicle. 2. Remove the front wheel and tire assembly 3. Remove disc brake caliper and rotor from steering knuckle. 4. Remove shock absorber. 5. Remove the strut bar. 6. Install Spring Compressor DD-1278, or equivalent. Use a piece of pipe to fabricate a spacer positioned between the tool and suspension arm. 7. Tighten tool nut against bell-shaped adapter tool finger-tight and loosen 1/2 of a turn. 8. Remove cotter pins and nuts from ball studs. 9. Position Ball Stud Remover C-3564-A, or equivalent and rotate threaded portion of tool to apply force to the lower ball stud. 10. Strike steering knuckle sharply with a hammer to loosen ball stud from knuckle. Do not force ball stud out from knuckle with the tool. 11. Remove ball stud seal. Use Remover/Installer C-4212F, or equivalent to press the ball stud from lower suspension arm bore. Lower Ball Stud Installation INSTALLATION Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement > Page 5179 1. Press new ball stud in lower suspension arm with Remover/Installer C-4212F, or equivalent. 2. Position new seal over ball stud and use a socket to force lip of seal until securely in place. 3. Position lower ball stud in steering knuckle. 4. Install retaining nut on the lower ball stud and tighten to: - 11/16-16 bolt: 183 Nm (135 ft. lbs.) - 3/4-16 bolt: 237 Nm (175 ft. lbs.) 5. Install new cotter pins. 6. Install the strut bar. 7. Remove spring compressor tool. Install shock absorber. 8. Install rotor and disc brake caliper. 9. Install wheel and tire assemble and lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement > Page 5180 Ball Joint: Service and Repair Upper Ball Joint Replacement REMOVAL 1. Place a jack under outer end of lower suspension arm. Raise and support the vehicle. 2. Remove wheel and tire assembly. 3. Remove cotter pin and nut from upper ball stud. 4. Position Ball Stud Remover C-3564-A, or equivalent between ball studs. Rotate threaded portion of tool to apply force to the upper ball stud. 5. Strike steering knuckle sharply with a hammer to loosen ball stud from knuckle. Do not force ball stud out from knuckle with the tool. 6. Remove ball stud seal. 7. Use Tool C-3561, or equivalent to unthread ball stud from suspension arm. INSTALLATION 1. Thread new ball stud in with Tool C-3561, or equivalent and tighten to 170 Nm (125 ft. lbs.). The gap between ball stud Hex and suspension arm bore is 0.25 - 1.25 mm (0.01 - 0.05 inch). 2. Install new seal over ball stud and securely locked in place. 3. Position steering knuckle on upper ball stud tighten nut to 183 Nm (135 ft. lbs.). Install a new cotter pin. 4. Install wheel and tire assembly and lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair Control Arm Bushing: Service and Repair REMOVAL 1. Remove lower control arm. 2. Use an arbor press and an appropriate size sleeve (driver) to force out old bushing. INSTALLATION 1. Use an arbor press and an appropriate size sleeve (driver) to install the new bushing. Ensure bushing is completely seated. 2. Install lower control arm. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation The steering knuckles are used to steer the vehicle. The knuckles are mounted to the ball studs at the end of the suspension arms. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation > Page 5188 Front Steering Knuckle: Service and Repair REMOVAL 1. Raise and support the vehicle. Place a jack under outer end of lower suspension arm. 2. Remove wheel and tire assembly. 3. Remove disc brake caliper and rotor. 4. Remove tie rod from steering knuckle arm. 5. Remove cotter pins and nuts from upper and lower ball joints. 6. Use Ball Stud Remover C-3564-A, or equivalent to free upper and lower ball joints from steering knuckle. 7. Remove tool and steering knuckle assembly. 8. Remove the rotor dust shield and steering arm from steering knuckle. INSTALLATION 1. Install brake rotor dust shield on steering knuckle and tighten bolts to 24 Nm (18 ft. lbs.). 2. Install steering arm on knuckle and tighten nuts to; - LD 5/8-18 nut: 294 Nm (217 ft. lbs.) - HD 3/4-16 nut: 330 Nm (225 ft. lbs.) 3. Position steering knuckle on upper and lower ball joints and install nuts. Tighten upper nut to 183 Nm (135 ft. lbs). Install new cotter pins. 4. Tighten the lower nut to: - LD 11/16-16 nut: 183 Nm (135 ft. lbs.) - HD 3/4-16 nut: 237 Nm (175 ft. lbs.) 5. Install tie rod to steering knuckle arm. 6. Install rotor and disc brake caliper. 7. Install wheel and tire assembly and lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut Bar <--> [Radius Arm] > Component Information > Specifications Strut Bar: Specifications Rear Nut .............................................................................................................................................. ..................................................... 71 Nm (52 ft. lbs.) Front Nuts ........................................................ ..................................................................................................................................... 136 Nm (100 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut Bar <--> [Radius Arm] > Component Information > Specifications > Page 5192 Strut Bar: Description and Operation The strut bar is used to control the movement of the lower control arm. The bar is mounted between the lower control arm and a frame bracket. The bar uses replaceable bushings to isolated it from the frame bracket. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut Bar <--> [Radius Arm] > Component Information > Specifications > Page 5193 Strut Bar: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove front tire and wheel assembly. 3. Remove the roll pin from the rear of the strut bar with a small punch and hammer. Strut Bar 4. Remove the nut, retainer and bushing from the rear of the strut bar. 5. Remove the stabilizer bar link from the strut bar. 6. Remove the jounce bumper/strut bar mounting nuts and bolts. 7. Remove the strut bar from the vehicle. Remove the bushing and inner retainer from the strut bar. INSTALLATION 1. Position the inner retainer and bushing on the strut bar. 2. Install strut through the frame rail hole. 3. Install jounce bumper/strut bar mounting bolts and nuts. Tighten the nuts to 136 Nm (100 ft. lbs.). 4. Install the rear bushing, retainer and nut on the strut bar. Tighten the nut to 71 Nm (52 ft. lbs.). 5. Install the stabilizer bar link to the strut bar. 6. Install the spring pin in the strut bar. 7. Install wheel and tire assembly. 8. Remove support and lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications Link Nuts .............................................................................................................................................. ............................................... 11 Nm (100 inch lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5206 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5207 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5208 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest: > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs Suspension Spring ( Coil / Leaf ): Customer Interest Squeaking/Clicking Noises From Rear Leaf Springs NUMBER: 02-04-00 Rev. A GROUP: Suspension DATE: May 12, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-04-00, DATED MAR. 17, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CORRECTION TO A PART NUMBER. SUBJECT: Squeaking/Clicking Noise From Rear Leaf Springs OVERVIEW: This bulletin involves replacing the spring tip liners and installing spring clinch clip isolators. MODELS: 1994 - 2000 (AB) Ram Van/Wagon 1994 - 2001 (BR/BE) Ram Truck SYMPTOM/CONDITION: Squeaking/clicking noise coming from the rear of the vehicle. DIAGNOSIS: If the customer indicates that the vehicle has a squeaking/clicking noise coming from the rear of the vehicle, verify that the noise is coming from the rear springs as the vehicle's suspension goes through jounce and rebound. If a squeaking/clicking noise is coming from the rear springs, perform the Repair Procedure. NOTE: PERFORM THE REPAIR PROCEDURE ON ANY VEHICLE THAT HAS MISSING TIP LINERS OR MISSING CLINCH CLIP ISOLATORS AND A SQUEAKING/CLICKING NOISE IS COMING FROM THE REAR SPRINGS. NOTE: RAM TRUCKS WERE NOT ORIGINALLY EQUIPPED WITH SPRING CLINCH CLIP ISOLATORS. PARTS REQUIRED: EQUIPMENT REQUIRED: Large C-Clamp (5-6 in.) Large Pry Bar Large Adjustable Pliers REPAIR PROCEDURE: 1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully). 2. On Ram Vans, remove both rear tire/wheel assemblies. 3. Position a large C-Clamp adjacent to the spring clinch clip and clamp the leaves of the spring together. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest: > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs > Page 5213 Figure 1 4. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 1). If necessary, remove the existing spring clinch clip isolators. Figure 2 5. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be enough to remove the old liner (if necessary) and install the replacement liner. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest: > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs > Page 5214 Figure 3 6. If necessary, remove the old spring tip liner (Figure 3). 7. With the prybar still inserted between the leaves, install a new spring tip liner (see Parts Required section) onto the leaf. Figure 4 8. Firmly seat the spring tip liner onto the leaf. A C-Clamp can be used to compress the adjacent leaves together (Figure 4) which will seat the liner retaining pin into the hole. NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. 9. Apply a small amount of lubricant p/n 05018626AA onto the tip liner wear pad. 10. Repeat Steps 5 through 9 to remove and install all rear spring tip liners. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest: > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs > Page 5215 Figure 5 11. Place one spring clinch clip isolator p/n **52113142AA** onto the outboard side of the spring clinch clip (Figure 5) and one isolator on the inboard side of the spring clinch clip. Figure 6 12. Using large adjustable pliers, close the spring clinch clip until the isolator contacts the leaf spring (Figure 6). CAUTION: DO NOT USE A HAMMER TO CLOSE THE SPRING CLINCH CLIP. DAMAGE TO THE ISOLATOR MAY RESULT. 13. Use an appropriate pry bar to bend open the front spring clinch clip. If necessary, remove the existing spring clinch clip isolators. 14. Perform Steps 5 through 12 to the front portion of the rear leaf spring assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest: > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs > Page 5216 15. Perform Steps 4 through 14 to the other side of the vehicle. 16. On Ram Van/Wagons, install the tire wheel assemblies. 17. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage NO: 14-03-98 GROUP: Fuel DATE: May 1, 1998 SUBJECT: Fuel Pressure Gauge Adapter Usage MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) DISCUSSION: Currently, four different fuel pressure adapters are required, depending on application, to attach a fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > System Information > Specifications > Pressure, Vacuum and Temperature Specifications Fuel Pressure: Pressure, Vacuum and Temperature Specifications Fuel Pressure Engine at curb idle ............................................................................................................................... ........................................ 339 ± 34 kPa (49.2 ± 5 psi) Pressure Leakdown (fuel pump not engaged) ................................................................................................................. Not fall below 30 psi for 5 minutes Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 5222 Fuel Pressure: Capacity Specifications NOTE: Before performing this test, verify fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. - Refer to the Fuel Pressure Release Procedure. 2. Disconnect the fuel supply line at fuel rail. - Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. - Insert other end of Adaptor Tool hose into a graduated container. 4. Remove the fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. - Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. - Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > System Information > System Diagnosis > Fuel Pressure Leak Down Test Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test Fig 9 Connecting Adaptor Tool -- Typical Fig. 8 Installing Adapter Tool And Pressure Gauge NOTE: Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: Fuel pressure bleeding past a fuel injector(s). - Fuel pressure bleeding past the check valve in the fuel pump module. 1. Disconnect the fuel inlet line at fuel rail. - On some engines, air cleaner housing removal may be necessary before fuel line disconnection. 2. Connect the appropriate Fuel Line Pressure Test Adapter Tool (number 6539, 6631, 6541 or 6923) between the disconnected fuel line and fuel rail (Fig. 9) or (Fig. 10). 3. Connect the 0-414 kPa (0-60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. - The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 4. Start engine and bring to normal operating temperature. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 5225 5. Observe test gauge. Normal operating pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). 6. Shut engine off. 7. Pressure should not fall below 30 psi for five minutes. 8. If pressure falls below 30 psi, it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 9. Again, start engine and bring to normal operating temperature. 10. Shut engine off. 11. Testing for fuel injector or fuel rail leakage: - Clamp off the rubber hose portion of Adaptor Tool between the fuel rail and the test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a fuel injector or the fuel rail is leaking. 12. Testing for fuel pump check valve, filter/regulator check valve or fuel tube/line leakage: - Clamp off the rubber hose portion of Adaptor Tool between the vehicle fuel line and test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a leak may be found at a fuel tube/line. - If no leaks are found at fuel tubes or lines, one of the check valves in either the electric fuel pump or filter/ regulator may be leaking. NOTE: A quick loss of pressure usually indicates a defective check valve in the filter/regulator. A slow loss of pressure usually indicates a defective check valve in the electric fuel pump. The electric fuel pump is not serviced separately -- Replace the fuel pump module assembly. The filter/ regulator may be replaced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/installation for additional information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 5226 Fuel Pressure: Testing and Inspection Fuel Pressure Test Fuel Pressure Test Gauge NOTE: Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test, fuel pump amperage test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow hack into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. WARNING: The fuel system is under constant fuel pressure even with the engine off. Before disconnecting fuel line at fuel rail, this pressure must be released. Refer to the fuel system pressure release procedure. NOTE: To perform this test you will need to remove the engine cover. 1. Remove the protective cap at the fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port pressure fitting on the fuel rail. 2. Start and warm the engine and note pressure gauge reading. Fuel pressure should be 3.39 kPa +/- 34 kPa (49.2 psi +/- 5 psi) at idle. 3. If engine runs but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, replace fuel pump module assembly. Refer to Fuel Pump Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel filter/fuel pressure regulator. Certain filter/regulators may be serviced separately and some require the replacement of the fuel pump module assembly Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 5227 Fuel Pressure: Testing and Inspection Fuel Pump Amperage Test This amperage (current draw) test is to be done in conjunction with the Fuel Pump Pressure Test, Fuel Pump Capacity Test and Fuel Pressure Leak Down Test. Before performing the amperage test, be sure the temperature of the fuel tank is above 50° F (10° C). The DRB Scan Tool along with the DRB Low Current Shunt (LCS) adapter and its test leads will be used to check fuel pump amperage specifications. Low Current Shunt Adapter 1. Obtain LCS adapter. 2. Plug cable from LCS adapter into DRB scan tool at SET 1 receptacle. 3. Plug DRB into vehicle 16-way connector (data link connector). 4. Connect (-) and (+) test cable leads into LCS adapter receptacles. Use 10 amp (10A +) receptacle and common (-) receptacles. 5. Gain access to MAIN MENU on DRB screen. 6. Press DVOM button on DRB. 7. Using left/right arrow keys, highlight CHANNEL 1 function on DRB screen. 8. Press ENTER three times. 9. Using up/down arrow keys, highlight RANGE on DRB screen (screen will default to 2 amp scale). 10. Press ENTER to change 2 amp scale to 10 amp scale. This step must be done to prevent damage to DRB scan tool or LCS adapter (blown fuse). 11. Remove cover from Power Distribution Center (PDC). 12. Remove fuel pump relay from PDC. Refer to label on PDC cover for relay location. WARNING: BEFORE PROCEEDING TO NEXT STEP, NOTE THE FUEL PUMP WILL BE ACTIVATED AND SYSTEM PRESSURE WILL BE PRESENT. THIS WILL OCCUR AFTER CONNECTING TEST LEADS FROM LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES. THE FUEL PUMP WILL OPERATE EVEN WITH IGNITION KEY IN OFF POSITION. BEFORE ATTACHING TEST LEADS, BE SURE ALL FUEL LINES AND FUEL SYSTEM COMPONENTS ARE CONNECTED. CAUTION: To prevent possible damage to the vehicle electrical system and LCS adapter, the test leads must be connected into relay cavities exactly as shown in following steps. Depending upon vehicle model, year or engine configuration, three different types of relays may be used: Type-1, type-2 and type-3. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 5228 Starter Relay 13 If equipped with type-1 relay, attach test leads from LCS adapter into PDC relay cavities number 30 and 87. For location of these cavities, refer to numbers stamped to bottom of relay. Type-2 Relay 14. If equipped with type-2 relay, attach test leads from LCS adapter into PDC relay cavities number 30 and 87. For location of these cavities, refer to numbers stamped to bottom of relay. Type-3 Relay 15. If equipped with type-3 relay, attach test leads from LCS adapter into PDC relay cavities number 3 and 5. For location of these cavities, refer to numbers stamped to bottom of relay. 16. When LCS adapter test leads are attached into relay cavities, fuel pump will be activated. Determine fuel pump amperage on DRB screen. Amperage should be below 10.0 amps. If amperage is below 10.0 amps, and specifications for the Fuel Pump Pressure, Fuel Pump Capacity and Fuel Pressure Leak Down tests were met, the fuel pump module is OK. 17. If amperage is more than 10.0 amps, replace fuel pump module assembly The electric fuel pump is not serviced separately. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 5229 18. Disconnect test leads from relay cavities immediately after testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 5230 Fuel Pressure: Testing and Inspection Fuel Pump Capacity Test NOTE: Before performing this test, verify fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. - Refer to the Fuel Pressure Release Procedure. 2. Disconnect the fuel supply line at fuel rail. - Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. - Insert other end of Adaptor Tool hose into a graduated container. 4. Remove the fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. - Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. - Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Spring ( Coil / Leaf ): > 18-19-98 > Apr > 98 > Customer Interest for Suspension Spring ( Coil / Leaf ): > 19-002-01A > Sep > 01 > Steering/Suspension Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Spring ( Coil / Leaf ): > 18-19-98 > Apr > 98 > Customer Interest for Suspension Spring ( Coil / Leaf ): > 19-002-01A > Sep > 01 > Steering/Suspension Wander Diagnosis/Repair > Page 5240 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Spring ( Coil / Leaf ): > 18-19-98 > Apr > 98 > Customer Interest for Suspension Spring ( Coil / Leaf ): > 19-002-01A > Sep > 01 > Steering/Suspension Wander Diagnosis/Repair > Page 5241 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Spring ( Coil / Leaf ): > 18-19-98 > Apr > 98 > Customer Interest for Suspension Spring ( Coil / Leaf ): > 19-002-01A > Sep > 01 > Steering/Suspension Wander Diagnosis/Repair > Page 5242 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Spring ( Coil / Leaf ): > 18-19-98 > Apr > 98 > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs Suspension Spring ( Coil / Leaf ): Customer Interest Squeaking/Clicking Noises From Rear Leaf Springs NUMBER: 02-04-00 Rev. A GROUP: Suspension DATE: May 12, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-04-00, DATED MAR. 17, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CORRECTION TO A PART NUMBER. SUBJECT: Squeaking/Clicking Noise From Rear Leaf Springs OVERVIEW: This bulletin involves replacing the spring tip liners and installing spring clinch clip isolators. MODELS: 1994 - 2000 (AB) Ram Van/Wagon 1994 - 2001 (BR/BE) Ram Truck SYMPTOM/CONDITION: Squeaking/clicking noise coming from the rear of the vehicle. DIAGNOSIS: If the customer indicates that the vehicle has a squeaking/clicking noise coming from the rear of the vehicle, verify that the noise is coming from the rear springs as the vehicle's suspension goes through jounce and rebound. If a squeaking/clicking noise is coming from the rear springs, perform the Repair Procedure. NOTE: PERFORM THE REPAIR PROCEDURE ON ANY VEHICLE THAT HAS MISSING TIP LINERS OR MISSING CLINCH CLIP ISOLATORS AND A SQUEAKING/CLICKING NOISE IS COMING FROM THE REAR SPRINGS. NOTE: RAM TRUCKS WERE NOT ORIGINALLY EQUIPPED WITH SPRING CLINCH CLIP ISOLATORS. PARTS REQUIRED: EQUIPMENT REQUIRED: Large C-Clamp (5-6 in.) Large Pry Bar Large Adjustable Pliers REPAIR PROCEDURE: 1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully). 2. On Ram Vans, remove both rear tire/wheel assemblies. 3. Position a large C-Clamp adjacent to the spring clinch clip and clamp the leaves of the spring together. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Spring ( Coil / Leaf ): > 18-19-98 > Apr > 98 > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs > Page 5247 Figure 1 4. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 1). If necessary, remove the existing spring clinch clip isolators. Figure 2 5. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be enough to remove the old liner (if necessary) and install the replacement liner. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Spring ( Coil / Leaf ): > 18-19-98 > Apr > 98 > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs > Page 5248 Figure 3 6. If necessary, remove the old spring tip liner (Figure 3). 7. With the prybar still inserted between the leaves, install a new spring tip liner (see Parts Required section) onto the leaf. Figure 4 8. Firmly seat the spring tip liner onto the leaf. A C-Clamp can be used to compress the adjacent leaves together (Figure 4) which will seat the liner retaining pin into the hole. NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. 9. Apply a small amount of lubricant p/n 05018626AA onto the tip liner wear pad. 10. Repeat Steps 5 through 9 to remove and install all rear spring tip liners. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Spring ( Coil / Leaf ): > 18-19-98 > Apr > 98 > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs > Page 5249 Figure 5 11. Place one spring clinch clip isolator p/n **52113142AA** onto the outboard side of the spring clinch clip (Figure 5) and one isolator on the inboard side of the spring clinch clip. Figure 6 12. Using large adjustable pliers, close the spring clinch clip until the isolator contacts the leaf spring (Figure 6). CAUTION: DO NOT USE A HAMMER TO CLOSE THE SPRING CLINCH CLIP. DAMAGE TO THE ISOLATOR MAY RESULT. 13. Use an appropriate pry bar to bend open the front spring clinch clip. If necessary, remove the existing spring clinch clip isolators. 14. Perform Steps 5 through 12 to the front portion of the rear leaf spring assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Spring ( Coil / Leaf ): > 18-19-98 > Apr > 98 > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs > Page 5250 15. Perform Steps 4 through 14 to the other side of the vehicle. 16. On Ram Van/Wagons, install the tire wheel assemblies. 17. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5258 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5259 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5260 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00 > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00 > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 5269 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Component Information > Technical Service Bulletins > Component Information > Service and Repair License Plate Bulb: Service and Repair REMOVAL - Base And Standard Bumper 1. Remove license plate. 2. Remove lamp. 3. Remove screws attaching lamp lens to housing. 4. Twist out bulb. INSTALLATION - Base And Standard Bumper 1. Install bulb in socket. 2. Install screws attaching lamp lens to housing. 3. Install lamp. 4. Install license plate. REMOVAL - Step Bumper 1. Remove lamp. 2. Remove bulb. INSTALLATION - Step Bumper 1. Install bulb. 2. Position lamp in bumper. 3. Install lamp. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay Power Door Lock Relay Parts OEM Part Price Lock Relay................................................................................................................................. 56006769 31.75 Contact Dealer for most current part and price information. Skill Mfg. Labor Level Warr. Std. Replace Door One................................................................................................................................... B 0.5 0.6 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Light Relay ABS Light Relay Skill Mfg. Labor Level Warr. Std. Replace Brake Warning Lamp Relay................................................................................................... B 0.2 0.3 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Light Relay > Page 5279 ABS Main Relay Skill Mfg. Labor Level Warr. Std. Replace Main Relay............................................................................................................................. B 0.2 0.3 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Light Relay > Page 5280 Electronic Brake Control Module Parts OEM Part Price ABS Control Module 2 Wheel ABS...................................................................................................................... 5018421AA 509.00 4 Wheel ABS...................................................................................................................... 5017705AA 424.00 Skill Mfg. Labor Level Warr. Std. Replace Control Module 2 Wheel ABS.................................................................................................................... B 0.7 1.0 4 Wheel ABS.................................................................................................................... B 0.5 0.7 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Relays and Modules > Relays and Modules - HVAC > System Relay System Relay Skill Mfg. Labor Level Warr. Std. Replace Main Heater & A/C Cut-Off Relay................................................................................................................... B 0.2 0.3 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Relays and Modules > Relays and Modules - Instrument Panel > ABS Light Relay ABS Light Relay Skill Mfg. Labor Level Warr. Std. Replace Brake Warning Lamp Relay................................................................................................... B 0.2 0.3 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit Daytime Running Lamp Control Unit Parts OEM Part Price DRL Module............................................................................................................................ 56021561 111.00 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Page 5287 Horn Relay Parts OEM Part Price Horn Relay................................................................................................................................. 4221658 10.70 Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ C 0.2 0.4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Powertrain Control Module Parts OEM Part Price ECM Federal................................................................................................................................ 56046318AE 625.00 Order By Description. California............................................................................................................................ 56046317AD 780.00 Order By Description. Skill Mfg. Labor Level Warr. Std. Replace ECM....................................................................................................................................... B 0.2 0.4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module > Page 5291 Automatic Shut Down (ASD) Relay Skill Mfg. Labor Level Warr. Std. Replace Auto Shutdown Relay............................................................................................................. B 0.2 0.3 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay Fuel Pump Relay Parts OEM Part Price Fuel Pump Relay........................................................................................................................ 56006904 34.50 Contact Dealer for most current part and price information. Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.2 0.3 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Page 5294 Automatic Shut Down (ASD) Relay Skill Mfg. Labor Level Warr. Std. Replace Auto Shutdown Relay............................................................................................................. B 0.2 0.3 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module Air Bag Control Module Parts OEM Part Price Energy Reserve Module From 4/3/95........................................................................................................................ 56043105 516.00 Contact Dealer for most current part and price information. Skill Mfg. Labor Level Warr. Std. Replace Energy Reserve Module......................................................................................................... B 0.3 0.5 WARNING: Before Repairing Any Air Restraint System, The Battery Cables And Any Back-up Power Supplies To The System Must Be Disconnected In Order To Prevent Accidental Deployment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay Starter Relay Parts OEM Part Price Relay.......................................................................................................................................... 4734970 21.00 Contact Dealer for most current part and price information. Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.2 0.4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay Power Window Relay Skill Mfg. Labor Level Warr. Std. Replace Front....................................................................................................................................... B 0.2 0.3 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay Wiper Relay Parts OEM Part Price Intermittent Relay....................................................................................................................... 56021564AB 67.00 Skill Mfg. Labor Level Warr. Std. Replace Intermittent Relay................................................................................................................... B 0.3 0.5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch Power Door Lock Switch Parts OEM Part Price Front Door Lock Switch Single............................................................................................................................. 56045010AA 23.70 Double............................................................................................................................ 56006897 42.45 Skill Mfg. Labor Level Warr. Std. Replace Front One................................................................................................................................... B 0.2 0.4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Page 5306 Power Mirror Switch Parts OEM Part Price Mirror Switch Full Size Van........................................................................................................................ 4360141 68.20 Contact Dealer for most current part and price information. Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.5 0.6 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Page 5307 Power Seat Switch Parts OEM Part Price Switch....................................................................................................................................... 4373666 123.00 Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.3 0.4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch Parking Brake Warning Switch Parts OEM Part Price Park Brake Warning Switch......................................................................................................... 4221463 8.70 Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ C 0.3 0.5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Page 5310 Wheel Speed Sensor Parts OEM Part Price Front Speed Sensor Right..................................................................................................................................... NOT LISTED 0.00 Left....................................................................................................................................... NOT LISTED 0.00 Rear Speed Sensor 2 Wheel ABS........................................................................................................................ 56028188AB 70.20 4 Wheel ABS........................................................................................................................ 4485165 82.45 Skill Mfg. Labor Level Warr. Std. Replace Front Speed Sensor One Side........................................................................................................................... B 0.6 0.9 Rear Speed Sensor Differential Mounted........................................................................................................ B 0.3 0.5 Differential Mounted. Rear Sensor Ring.................................................................................................................... B 2.1 2.9 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) Coolant Temperature Sensor/Switch (For Computer) Parts OEM Part Price Coolant Temp Sensor................................................................................................................. 56004815 51.85 Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.3 0.7 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Page 5314 Temperature Sensor (Gauge) Parts OEM Part Price Temp Sending Unit.................................................................................................................... 56027011 19.25 Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.3 0.5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) Brake Switch (Cruise Control) Parts OEM Part Price Brake Switch.............................................................................................................................. 4671336 26.70 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Page 5317 Cruise Control Switch Parts OEM Part Price Engagement Switch Right..................................................................................................................................... 56021332 63.35 Left....................................................................................................................................... 56021333 28.30 Skill Mfg. Labor Level Warr. Std. Replace Engagement Switch................................................................................................................ B 0.2 0.4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender Oil Pressure Sender Parts OEM Part Price Oil Pressure Sending Unit.......................................................................................................... 56031005 57.50 Skill Mfg. Labor Level Warr. Std. Replace With Light.............................................................................................................................. B 0.4 0.7 With Gauge............................................................................................................................ B 0.5 0.8 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch > Component Information > Low Pressure Sensor / Switch Low Pressure Sensor / Switch Parts OEM Part Price Low Pressure Cut-Off Switch Front..................................................................................................................................... 55036079AB 75.75 Contact Dealer for most current part and price information. Rear...................................................................................................................................... NOT LISTED 0.00 Skill Mfg. Labor Level Warr. Std. Replace Low Pressure Cut-Off Switch Front Unit......................................................................................................................... B 0.5 0.8 Does Not Include: Refrigerant Recovery Or Evacuate & Recharge AC System. Front & Rear Unit............................................................................................................ B 0.8 1.1 Does Not Include: Refrigerant Recovery Or Evacuate & Recharge AC System. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch > Component Information > Page 5324 Refrigerant Pressure Sensor / Switch Skill Mfg. Labor Level Warr. Std. Replace Pressure Cycling Switch Without Rear AC.............................................................................................................. B 2.7 3.8 Does Not Include: Refrigerant Recovery Or Evacuate & Recharge AC System. With Rear AC................................................................................................................... B 2.9 4.1 Does Not Include: Refrigerant Recovery Or Evacuate & Recharge AC System. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch > Page 5325 Blower Motor Switch Parts OEM Part Price Main Blower Motor Blower Motor Switch Without AC.................................................................................................................... 55036176 4.75 With AC......................................................................................................................... 4261306 40.20 Auxiliary Blower Motor Blower Motor Switch Without AC.................................................................................................................... 55036023 4.35 With AC......................................................................................................................... 55036012 48.60 Skill Mfg. Labor Level Warr. Std. Replace With AC................................................................................................................................. B 0.5 0.8 Without AC............................................................................................................................ B 0.4 0.7 Auxiliary Heater & A/C......................................................................................................... B 0.3 0.5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch > Page 5326 Fin Sensing Cycling Clutch Switch Parts OEM Part Price Auxiliary Air Conditioner Temp Switch.......................................................................................................................... NOT LISTED 0.00 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch Door Switch Parts OEM Part Price Door Jamb Switch...................................................................................................................... 4565004AB 74.20 Skill Mfg. Labor Level Warr. Std. Replace One......................................................................................................................................... C 0.2 0.4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Page 5329 Fuel Gauge Sender Parts OEM Part Price Fuel Gauge Sending Unit 32 Gallon Tank..................................................................................................................... 5012269AA 93.10 35 Gallon Tank..................................................................................................................... 5012270AA 93.60 Skill Mfg. Labor Level Warr. Std. Replace Without Steel Tank................................................................................................................. B 1.4 2.3 Does Not Include: Drain & Refill Fuel Tank. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Page 5330 Parking Brake Warning Switch Parts OEM Part Price Park Brake Warning Switch......................................................................................................... 4221463 8.70 Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ C 0.3 0.5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch Backup Lamp Switch Parts Back-Up Switch Auto Trans See Neutral Safety Switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Page 5333 Brake Light Switch Parts OEM Part Price Stoplamp Switch......................................................................................................................... 4671336 26.70 Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.3 0.5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Page 5334 Combination Switch Parts OEM Part Price Turn Signal & Hazard Switch.................................................................................................. 4728424 130.00 Skill Mfg. Labor Level Warr. Std. Replace Turn Signal & Hazard Switch Without Tilt Wheel.......................................................................................................... B 0.4 0.7 With Tilt Wheel................................................................................................................ B 0.4 0.7 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Page 5335 Door Switch Parts OEM Part Price Door Jamb Switch...................................................................................................................... 4565004AB 74.20 Skill Mfg. Labor Level Warr. Std. Replace One......................................................................................................................................... C 0.2 0.4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Page 5336 Hazard Warning Switch Parts OEM Part Price Turn Signal & Hazard Switch.................................................................................................. 4728424 130.00 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Page 5337 Headlamp Dimmer Switch Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.4 0.7 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Page 5338 Headlamp Switch Parts OEM Part Price Headlamp Switch....................................................................................................................... 56021889AA 71.20 Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.4 1.0 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Page 5339 Horn Switch Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ C 0.3 0.5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Page 5340 Turn Signal Switch Parts OEM Part Price Turn Signal & Hazard Switch.................................................................................................. 4728424 130.00 Skill Mfg. Labor Level Warr. Std. Replace Turn Signal & Hazard Switch Without Tilt Wheel.......................................................................................................... B 0.4 0.7 With Tilt Wheel................................................................................................................ B 0.4 0.7 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor Battery Temperature Sensor Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.0 0.5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Page 5344 Camshaft Position Sensor Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.3 0.6 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Page 5345 Coolant Temperature Sensor/Switch (For Computer) Parts OEM Part Price Coolant Temp Sensor................................................................................................................. 56004815 51.85 Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.3 0.7 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Page 5346 Crankshaft Position Sensor Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.4 0.7 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Page 5347 Intake Air Temperature Sensor Parts OEM Part Price Air Intake Temp Sensor............................................................................................................. 56027872 59.80 Skill Mfg. Labor Level Warr. Std. Replace Air Intake Temp Sensor......................................................................................................... B 0.4 0.7 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Page 5348 Manifold Pressure/Vacuum Sensor Parts OEM Part Price MAP Sensor............................................................................................................................. 56029405 123.00 Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.4 0.4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Page 5349 Oxygen Sensor Skill Mfg. Labor Level Warr. Std. Replace One......................................................................................................................................... B 0.3 0.4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Page 5350 Throttle Position Sensor Parts OEM Part Price Throttle Position Sensor With EFI............................................................................................................................... 4882219 48.00 Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.3 0.7 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Page 5351 Transmission Position Switch/Sensor Parts OEM Part Price Neutral Safety Switch 2 - A518 46RH, 46RE.......................................................................................................... 56028181 12.00 6 - A727/36RH/36RE........................................................................................................... 3747361 19.70 7 - A998/32RH, A999.......................................................................................................... 56028181 12.00 Skill Mfg. Labor Level Warr. Std. Replace A518 46RH, 46RE Range Sensor.................................................................................................................... B 0.0 0.5 A998/32RH, A999 Range Sensor.................................................................................................................... B 0.0 0.5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Page 5352 Vehicle Speed Sensor Parts OEM Part Price Vehicle Speed Sensor................................................................................................................. 56028183 46.30 Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.0 0.4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor Throttle Position Sensor Parts OEM Part Price Throttle Position Sensor With EFI............................................................................................................................... 4882219 48.00 Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.3 0.7 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Ignition Switch Lock Cylinder Ignition Switch Lock Cylinder Parts OEM Part Price Ignition Lock Cylinder............................................................................................................... 5010182AA 78.85 Skill Mfg. Labor Level Warr. Std. Replace Without Tilt Wheel................................................................................................................ B 0.0 0.6 With Tilt Wheel...................................................................................................................... B 0.4 0.7 Note To Recode Cylinder, Add................................................................................................. B 0.2 0.4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Page 5359 Ignition Switch Parts OEM Part Price Ignition Switch......................................................................................................................... 5010203AA 152.00 Skill Mfg. Labor Level Warr. Std. Replace Without Tilt Wheel................................................................................................................ B 0.5 0.8 With Tilt Wheel...................................................................................................................... B 0.4 0.7 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Page 5360 Camshaft Position Sensor Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.3 0.6 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Page 5361 Crankshaft Position Sensor Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.4 0.7 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch Air Bag Deactivation Switch Parts OEM Part Price Disable Switch.......................................................................................................................... 56045200AA 164.00 Contact Dealer for most current part and price information. Skill Mfg. Labor Level Warr. Std. Replace Disable Switch........................................................................................................................ B 0.4 0.5 WARNING: Before Repairing Any Air Restraint System, The Battery Cables And Any Back-up Power Supplies To The System Must Be Disconnected In Order To Prevent Accidental Deployment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Ignition Switch Lock Cylinder Ignition Switch Lock Cylinder Parts OEM Part Price Ignition Lock Cylinder............................................................................................................... 5010182AA 78.85 Skill Mfg. Labor Level Warr. Std. Replace Without Tilt Wheel................................................................................................................ B 0.0 0.6 With Tilt Wheel...................................................................................................................... B 0.4 0.7 Note To Recode Cylinder, Add................................................................................................. B 0.2 0.4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Page 5368 Ignition Switch Parts OEM Part Price Ignition Switch......................................................................................................................... 5010203AA 152.00 Skill Mfg. Labor Level Warr. Std. Replace Without Tilt Wheel................................................................................................................ B 0.5 0.8 With Tilt Wheel...................................................................................................................... B 0.4 0.7 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Page 5369 Battery Temperature Sensor Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.0 0.5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Page 5370 Neutral Safety Switch Parts OEM Part Price Back-Up Switch Auto Trans See Neutral Safety Switch. Neutral Safety Switch................................................................................................................. 56028181 12.00 Skill Mfg. Labor Level Warr. Std. Replace........................................................................................................................................ B 0.3 0.5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch Fluid Pressure Sensor/Switch Skill Mfg. Labor Level Warr. Std. Replace A518 46RH, 46RE................................................................................................................. B 1.1 1.4 Includes: R&I; Transmission Oil Pan. A727/36RH/36RE.................................................................................................................. B 1.1 1.4 Includes: R&I; Transmission Oil Pan. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch > Page 5374 Transmission Position Switch/Sensor Parts OEM Part Price Neutral Safety Switch 2 - A518 46RH, 46RE.......................................................................................................... 56028181 12.00 6 - A727/36RH/36RE........................................................................................................... 3747361 19.70 7 - A998/32RH, A999.......................................................................................................... 56028181 12.00 Skill Mfg. Labor Level Warr. Std. Replace A518 46RH, 46RE Range Sensor.................................................................................................................... B 0.0 0.5 A998/32RH, A999 Range Sensor.................................................................................................................... B 0.0 0.5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch > Page 5375 Transmission Speed Sensor Skill Mfg. Labor Level Warr. Std. Replace A518 46RH, 46RE Output Sensor................................................................................................................... B 0.5 0.6 Input Sensor..................................................................................................................... B 0.3 0.4 A727/36RH/36RE Range Sensor.................................................................................................................... B 0.0 0.5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch Heated Glass Element Switch Parts Switch Part of Dash Control Part of Dash Control Unit. Skill Mfg. Labor Level Warr. Std. Replace Switch..................................................................................................................................... B 0.3 0.5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Page 5378 Rear Defogger Switch Parts Switch Part of Dash Control Part of Dash Control Unit. Skill Mfg. Labor Level Warr. Std. Replace Switch..................................................................................................................................... B 0.3 0.5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Page 5379 Power Window Switch Parts OEM Part Price Front Door Window Switch Left................................................................................................................................. 56006897 42.45 Right............................................................................................................................... 56045010AA 23.70 Skill Mfg. Labor Level Warr. Std. Replace Front One................................................................................................................................... B 0.2 0.4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch Washer Fluid Level Switch Parts OEM Part Price Fluid Level Sensor..................................................................................................................... 4882797 16.75 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Page 5382 Wiper Switch Parts Wiper Switch Part of Turn Signal Switch. Part of Turn Signal Switch. Skill Mfg. Labor Level Warr. Std. Replace Without Tilt Wheel................................................................................................................ B 0.4 0.7 With Tilt Wheel...................................................................................................................... B 0.4 0.7 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Maintenance > System Information > Alignment Alignment Skill Mfg. Labor Level Warr. Std. Inspect Rear Suspension..................................................................................................................... B 0.0 0.5 Align Front Toe-In, Adjust............................................................................................................... B 0.0 0.7 Front Wheel Alignment.......................................................................................................... B 0.0 1.4 Rear Wheel Alignment Check............................................................................................................................... B 0.0 0.5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Maintenance > System Information > Page 5386 Maintenance Skill Mfg. Labor Level Warr. Std. Service or Charge Normal Service 7,500 Miles....................................................................................................................... C 0.0 0.7 15,000 Miles..................................................................................................................... C 0.0 0.9 22,500, Miles.................................................................................................................... C 0.0 1.2 30,000 Miles..................................................................................................................... B 0.0 2.3 37,500 Miles..................................................................................................................... C 0.0 0.7 45,000 Miles..................................................................................................................... C 0.0 1.8 52,500 Miles With Coolant Flush.................................................................................................... C 0.0 1.2 Without Coolant Flush............................................................................................... C 0.0 0.7 60,000 Miles..................................................................................................................... B 0.0 3.4 67,500 Miles..................................................................................................................... C 0.0 1.2 75,000 Miles With Coolant Flush.................................................................................................... C 0.0 1.3 Without Coolant Flush............................................................................................... C 0.0 0.8 82,500 Miles With Coolant Flush.................................................................................................... C 0.0 1.2 Without Coolant Flush............................................................................................... C 0.0 0.7 90,000 Miles..................................................................................................................... B 0.0 2.7 97,500 Miles..................................................................................................................... C 0.0 0.7 105,000 Miles With Coolant Flush.................................................................................................... C 0.0 1.4 Without Coolant Flush............................................................................................... C 0.0 0.9 112,500 Miles With Coolant Flush.................................................................................................... C 0.0 1.6 Without Coolant Flush............................................................................................... C 0.0 1.1 120,000 Miles................................................................................................................... B 0.0 3.4 127,500 Miles................................................................................................................... C 0.0 0.7 135,000 Miles With Coolant Flush.................................................................................................... C 0.0 1.8 Without Coolant Flush............................................................................................... C 0.0 1.3 142,500, Miles With Coolant Flush.................................................................................................... C 0.0 1.2 Without Coolant Flush............................................................................................... C 0.0 0.7 150,000 Miles................................................................................................................... B 0.0 2.3 Severe Service 3,000 Miles....................................................................................................................... C 0.0 0.7 6,000 Miles....................................................................................................................... C 0.0 1.0 9,000 Miles....................................................................................................................... C 0.0 0.7 12,000 Miles..................................................................................................................... C 0.0 2.6 15,000 Miles..................................................................................................................... C 0.0 1.2 18,000 Miles..................................................................................................................... C 0.0 1.0 21,000 Miles..................................................................................................................... C 0.0 0.9 24,000 Miles..................................................................................................................... C 0.0 2.5 27,000 Miles..................................................................................................................... C 0.0 0.7 30,000 Miles..................................................................................................................... C 0.0 2.9 33,000 Miles..................................................................................................................... C 0.0 0.7 36,000 Miles..................................................................................................................... C 0.0 2.6 39,000 Miles..................................................................................................................... C 0.0 0.7 42,000 Miles..................................................................................................................... C 0.0 1.2 45,000 Miles..................................................................................................................... C 0.0 1.2 48,000 Miles..................................................................................................................... C 0.0 3.1 51,000 Miles With Coolant Flush.................................................................................................... C 0.0 1.2 Without Coolant Flush............................................................................................... C 0.0 0.7 54,000 Miles..................................................................................................................... C 0.0 1.0 57,000 Miles..................................................................................................................... C 0.0 0.7 60,000 Miles Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Parts and Labor > Maintenance > System Information > Page 5387 Federal........................................................................................................................ B 0.0 5.9 California.................................................................................................................... B 0.0 5.5 63,000 Miles..................................................................................................................... C 0.0 0.9 66,000 Miles..................................................................................................................... C 0.0 1.0 69,000 Miles..................................................................................................................... C 0.0 0.7 72,000 Miles..................................................................................................................... C 0.0 2.6 75,000 Miles..................................................................................................................... C 0.0 1.2 78,000 Miles..................................................................................................................... C 0.0 1.0 81,000 Miles With Coolant Flush.................................................................................................... C 0.0 1.3 Without Coolant Flush............................................................................................... C 0.0 0.8 84,000 Miles..................................................................................................................... C 0.0 2.6 87,000 Miles..................................................................................................................... C 0.0 0.7 90,000 Miles..................................................................................................................... C 0.0 2.9 93,000 Miles..................................................................................................................... C 0.0 0.7 96,000 Miles..................................................................................................................... C 0.0 2.6 99,000 Miles..................................................................................................................... C 0.0 0.7 102,000 Miles................................................................................................................... C 0.0 1.0 105,000 Miles................................................................................................................... C 0.0 1.4 108,000 Miles................................................................................................................... C 0.0 2.6 111,000 Miles With Coolant Flush.................................................................................................... C 0.0 1.2 Without Coolant Flush............................................................................................... C 0.0 0.7 114,000 Miles................................................................................................................... C 0.0 1.0 117,000 Miles................................................................................................................... C 0.0 0.7 120,000 Miles Federal........................................................................................................................ B 0.0 5.9 California.................................................................................................................... B 0.0 5.5 123,000 Miles................................................................................................................... C 0.0 0.7 126,000 Miles................................................................................................................... C 0.0 1.2 129,000 Miles................................................................................................................... C 0.0 0.7 132,000 Miles................................................................................................................... C 0.0 2.6 135,000 Miles................................................................................................................... C 0.0 1.2 138,000 Miles................................................................................................................... C 0.0 1.0 141,000 Miles With Coolant Flush.................................................................................................... C 0.0 1.2 Without Coolant Flush............................................................................................... C 0.0 0.7 144,000 Miles................................................................................................................... C 0.0 2.6 147,000 Miles................................................................................................................... C 0.0 0.9 150,000 Miles................................................................................................................... C 0.0 2.9 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5395 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5396 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5397 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs Suspension Spring ( Coil / Leaf ): Customer Interest Squeaking/Clicking Noises From Rear Leaf Springs NUMBER: 02-04-00 Rev. A GROUP: Suspension DATE: May 12, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-04-00, DATED MAR. 17, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CORRECTION TO A PART NUMBER. SUBJECT: Squeaking/Clicking Noise From Rear Leaf Springs OVERVIEW: This bulletin involves replacing the spring tip liners and installing spring clinch clip isolators. MODELS: 1994 - 2000 (AB) Ram Van/Wagon 1994 - 2001 (BR/BE) Ram Truck SYMPTOM/CONDITION: Squeaking/clicking noise coming from the rear of the vehicle. DIAGNOSIS: If the customer indicates that the vehicle has a squeaking/clicking noise coming from the rear of the vehicle, verify that the noise is coming from the rear springs as the vehicle's suspension goes through jounce and rebound. If a squeaking/clicking noise is coming from the rear springs, perform the Repair Procedure. NOTE: PERFORM THE REPAIR PROCEDURE ON ANY VEHICLE THAT HAS MISSING TIP LINERS OR MISSING CLINCH CLIP ISOLATORS AND A SQUEAKING/CLICKING NOISE IS COMING FROM THE REAR SPRINGS. NOTE: RAM TRUCKS WERE NOT ORIGINALLY EQUIPPED WITH SPRING CLINCH CLIP ISOLATORS. PARTS REQUIRED: EQUIPMENT REQUIRED: Large C-Clamp (5-6 in.) Large Pry Bar Large Adjustable Pliers REPAIR PROCEDURE: 1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully). 2. On Ram Vans, remove both rear tire/wheel assemblies. 3. Position a large C-Clamp adjacent to the spring clinch clip and clamp the leaves of the spring together. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs > Page 5402 Figure 1 4. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 1). If necessary, remove the existing spring clinch clip isolators. Figure 2 5. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be enough to remove the old liner (if necessary) and install the replacement liner. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs > Page 5403 Figure 3 6. If necessary, remove the old spring tip liner (Figure 3). 7. With the prybar still inserted between the leaves, install a new spring tip liner (see Parts Required section) onto the leaf. Figure 4 8. Firmly seat the spring tip liner onto the leaf. A C-Clamp can be used to compress the adjacent leaves together (Figure 4) which will seat the liner retaining pin into the hole. NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. 9. Apply a small amount of lubricant p/n 05018626AA onto the tip liner wear pad. 10. Repeat Steps 5 through 9 to remove and install all rear spring tip liners. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs > Page 5404 Figure 5 11. Place one spring clinch clip isolator p/n **52113142AA** onto the outboard side of the spring clinch clip (Figure 5) and one isolator on the inboard side of the spring clinch clip. Figure 6 12. Using large adjustable pliers, close the spring clinch clip until the isolator contacts the leaf spring (Figure 6). CAUTION: DO NOT USE A HAMMER TO CLOSE THE SPRING CLINCH CLIP. DAMAGE TO THE ISOLATOR MAY RESULT. 13. Use an appropriate pry bar to bend open the front spring clinch clip. If necessary, remove the existing spring clinch clip isolators. 14. Perform Steps 5 through 12 to the front portion of the rear leaf spring assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs > Page 5405 15. Perform Steps 4 through 14 to the other side of the vehicle. 16. On Ram Van/Wagons, install the tire wheel assemblies. 17. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5411 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5412 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5413 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Squeaking/Clicking Noises From Rear Leaf Springs NUMBER: 02-04-00 Rev. A GROUP: Suspension DATE: May 12, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-04-00, DATED MAR. 17, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CORRECTION TO A PART NUMBER. SUBJECT: Squeaking/Clicking Noise From Rear Leaf Springs OVERVIEW: This bulletin involves replacing the spring tip liners and installing spring clinch clip isolators. MODELS: 1994 - 2000 (AB) Ram Van/Wagon 1994 - 2001 (BR/BE) Ram Truck SYMPTOM/CONDITION: Squeaking/clicking noise coming from the rear of the vehicle. DIAGNOSIS: If the customer indicates that the vehicle has a squeaking/clicking noise coming from the rear of the vehicle, verify that the noise is coming from the rear springs as the vehicle's suspension goes through jounce and rebound. If a squeaking/clicking noise is coming from the rear springs, perform the Repair Procedure. NOTE: PERFORM THE REPAIR PROCEDURE ON ANY VEHICLE THAT HAS MISSING TIP LINERS OR MISSING CLINCH CLIP ISOLATORS AND A SQUEAKING/CLICKING NOISE IS COMING FROM THE REAR SPRINGS. NOTE: RAM TRUCKS WERE NOT ORIGINALLY EQUIPPED WITH SPRING CLINCH CLIP ISOLATORS. PARTS REQUIRED: EQUIPMENT REQUIRED: Large C-Clamp (5-6 in.) Large Pry Bar Large Adjustable Pliers REPAIR PROCEDURE: 1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully). 2. On Ram Vans, remove both rear tire/wheel assemblies. 3. Position a large C-Clamp adjacent to the spring clinch clip and clamp the leaves of the spring together. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs > Page 5418 Figure 1 4. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 1). If necessary, remove the existing spring clinch clip isolators. Figure 2 5. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be enough to remove the old liner (if necessary) and install the replacement liner. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs > Page 5419 Figure 3 6. If necessary, remove the old spring tip liner (Figure 3). 7. With the prybar still inserted between the leaves, install a new spring tip liner (see Parts Required section) onto the leaf. Figure 4 8. Firmly seat the spring tip liner onto the leaf. A C-Clamp can be used to compress the adjacent leaves together (Figure 4) which will seat the liner retaining pin into the hole. NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. 9. Apply a small amount of lubricant p/n 05018626AA onto the tip liner wear pad. 10. Repeat Steps 5 through 9 to remove and install all rear spring tip liners. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs > Page 5420 Figure 5 11. Place one spring clinch clip isolator p/n **52113142AA** onto the outboard side of the spring clinch clip (Figure 5) and one isolator on the inboard side of the spring clinch clip. Figure 6 12. Using large adjustable pliers, close the spring clinch clip until the isolator contacts the leaf spring (Figure 6). CAUTION: DO NOT USE A HAMMER TO CLOSE THE SPRING CLINCH CLIP. DAMAGE TO THE ISOLATOR MAY RESULT. 13. Use an appropriate pry bar to bend open the front spring clinch clip. If necessary, remove the existing spring clinch clip isolators. 14. Perform Steps 5 through 12 to the front portion of the rear leaf spring assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs > Page 5421 15. Perform Steps 4 through 14 to the other side of the vehicle. 16. On Ram Van/Wagons, install the tire wheel assemblies. 17. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Page 5422 Suspension Spring ( Coil / Leaf ): Specifications U-Bolts Nuts ........................................................................................................................................ ................................................... 115 Nm (85 ft. lbs.) Shackle Eye Nut .............................................. ..................................................................................................................................... 149 Nm (110 ft. lbs.) Shackle Bracket Bolts .............................................................................................................. ................................................................. 47 Nm (35 ft. lbs.) Front Spring Eye Nut ........................... ................................................................................................................................................... 122 Nm (90 ft. lbs.) Rear Spring Eye Nut ................................................................................................... .......................................................................... 149 Nm (110 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Coil Springs Suspension Spring ( Coil / Leaf ): Description and Operation Coil Springs The coil springs control ride quality and maintain proper ride height. The coil springs mount between the frame and lower control arm. An isolator is located between the spring and frame to help isolate noise. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Coil Springs > Page 5425 Suspension Spring ( Coil / Leaf ): Description and Operation Leaf Springs The rear suspension system uses a multi-leaf springs and a solid drive axle. The forward end of the springs are mounted to the body rail hangers through rubber bushings. The rearward end of the springs are attached to the body by the use of shackles. The spring and shackles use rubber bushings. The bushing help to isolate road noise. The shackles allow the springs to change their length as the vehicle moves over various road conditions. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Page 5426 Suspension Spring ( Coil / Leaf ): Testing and Inspection If the vehicle is used for severe, off-road operation. the springs should be examined periodically. Check for broken and shifted leafs, loose and missing clips, and broken center bolts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Coil Springs Suspension Spring ( Coil / Leaf ): Service and Repair Coil Springs REMOVAL 1. Raise and support vehicle. 2. Remove front wheel and tire assembly. 3. Remove disc brake caliper from steering knuckle. 4. Disconnect the stabilizer bar and strut bar from the lower suspension arm. 5. Remove the shock absorber. Coil Spring 6. Install Spring Compressor DD-1278, or equivalent up through the lower suspension arm, coil spring and shock hole in the frame. 7. Tighten the spring compressor to compress spring. NOTE: This will hold the spring in place until the lower suspension arm is separated from the steering knuckle. 8. Remove the cotter pin and lower ball joint nut at the steering knuckle. 9. Install Ball Joint Remover C-3564-A, or equivalent on the lower ball joint. Turn the threaded portion of the tool and lock securely against the lower joint. 10. Expand the tool enough to place force on the lower ball joint. Strike the steering knuckle sharply with a hammer to loosen the joint. Do not attempt to force the joint out of the steering knuckle with the loosening tool. 11. Remove the spring compressor tool and pivot the lower suspension arm downward. 12. Remove coil spring and isolator pad from the vehicle. INSTALLATION 1. Tape the isolator pad to the tap of the coil spring. Position the spring in the lower suspension arm well. Be sure that the coil spring is seated in the well. The flat or closed end of the coil spring is the top. The ramped or open end of the coil spring is the bottom. 2. Install Spring Compressor DD-1278, or equivalent up through the lower suspension arm, coil spring and shock hole in frame. 3. Tighten the tool nut to compress the coil spring 4. Position the lower ball joint in steering knuckle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Coil Springs > Page 5429 5. Install the retaining nut on the lower ball joint and tighten to: - LD 11/16-16 bolt: 183 Nm (135 ft. lbs.). - HD 3/4-16 bolt: 237 Nm (175 ft. lbs.). 6. Install new cotter pins. 7. Install the strut bar. 8. Remove the spring compressor tool. 9. Install the stabilizer bar. 10. Install the shock absorber. 11. Install disc brake caliper. 12. Install wheel and tire assembly and lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Coil Springs > Page 5430 Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Bushing DISASSEMBLE 1. Remove the spring from the vehicle. 2. Position the spring eye in a press. 3. Press the bushing out with an appropriate size driver. ASSEMBLE 1. Press new bushing into the spring eye with an appropriate size driver. NOTE: Bushing must be centered in the spring eye. 2. Install the spring on the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Coil Springs > Page 5431 Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Replacement CAUTION: The rear of the vehicle must be lifted only with a jack or hoist. The lift must be placed under the frame rail crossmember located aft of the rear axle. Use care to avoid bending the side rail flange. REMOVAL 1. Raise the vehicle at the frame. 2. Use a hydraulic jack to relieve the axle weight. 3. Remove wheel and tire assembly. Rear Spring 4. Remove the U-bolt nuts, spring plate, U-bolts and spring seat from the axle. 5. Remove the nut and bolt from the shackle mounting bracket. 6. Remove the nut and bolt from the rear spring eye. 7. Remove the spring from the vehicle. 8. Remove the nut and bolt from the rear spring eye and remove the shackle. INSTALLATION 1. Install the spring shackle to the rear spring eye. Install the bolt and nut and tighten the nut finger tight. 2. Position the spring on the rear axle pad. Make sure the spring center bolt is inserted in the pad locating hole. 3. Align the spring front eye attaching nut finger tight. 4. Align the spring shackle eye with the bolt hole in the shackle bracket. Install the bolt and nut and tighten the nut finger tight. NOTE: When installing a rear spring, ensure rear spring eye is located above the shackle bracket pivot bolt. 5. Install the spring seat, U-bolts, spring plate and nuts. Tighten the U-bolt nuts to 115 Nm (85 ft. lbs.). 6. Install wheel and tire assembly. 7. Remove the support stands and lower the vehicle. 8. Tighten the front spring eye nut to 122 Nm (90 ft. lbs.). 9. Tighten the shackle nuts to 149 Nm (110 ft. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5440 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5441 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5442 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 5448 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 5449 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 21-04-00 > Jun > 00 > Customer Interest for Suspension Strut / Shock Absorber: > 19-002-01A > Sep > 01 > Steering/Suspension Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 21-04-00 > Jun > 00 > Customer Interest for Suspension Strut / Shock Absorber: > 19-002-01A > Sep > 01 > Steering/Suspension Wander Diagnosis/Repair > Page 5459 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 21-04-00 > Jun > 00 > Customer Interest for Suspension Strut / Shock Absorber: > 19-002-01A > Sep > 01 > Steering/Suspension Wander Diagnosis/Repair > Page 5460 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 21-04-00 > Jun > 00 > Customer Interest for Suspension Strut / Shock Absorber: > 19-002-01A > Sep > 01 > Steering/Suspension Wander Diagnosis/Repair > Page 5461 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5467 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5468 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5469 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Component Information > Locations > Page 5472 Camshaft Position Sensor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Component Information > Locations > Page 5473 Camshaft Position Sensor: Description and Operation SYSTEM OPERATION The camshaft position sensor is located in the distributor on all engines. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Component Information > Locations > Page 5474 Camshaft Position Sensor: Testing and Inspection Camshaft Position Sensor - Typical The camshaft position sensor is located in the distributor on all engines. To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostics Procedures service. To test the sensor only, refer to the following: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Remove engine cover. 2. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. For wire identification. 3. Connect the negative (-) voltmeter lead into the ground wire. For wire identification. 4. Set the voltmeter to the 15 Volt DC scale. 5. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 6. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 7. If voltage is not present, check the voltmeter leads for a good connection. 8. If voltage is still not present, check for voltage at the supply wire. For wire identification. 9. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 10. If voltage is still not present, perform vehicle test using the DRB scan tool. 11. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM. If continuity is not present, repair the harness as necessary c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 12. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Component Information > Locations > Page 5475 Camshaft Position Sensor: Service and Repair The camshaft position sensor is located in the distributor. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove engine cover. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. Crankshaft Position Sensor 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Component Information > Page 5476 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 5485 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 5486 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 5492 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 5493 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Component Information > Technical Service Bulletins > Page 5494 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Component Information > Page 5495 Camshaft Position Sensor: Service and Repair The camshaft position sensor is located in the distributor. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove engine cover. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. Crankshaft Position Sensor 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install engine cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear Vehicle: Application and ID Body Code Identification VEHICLE BODY CODE Ram Van AB Ram Wagon Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Description and Operation > Front Suspension Travel Bumper: Description and Operation Front The jounce bumpers are used to limit the travel of the suspension jounce and rebound motion. The replaceable bumpers are mounted to the upper and lower suspension arm. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Description and Operation > Front > Page 5502 Suspension Travel Bumper: Description and Operation Rear The jounce bumpers are used to limit the spring and axle travel. They are bolted to the body rail above the axle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5511 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5512 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5513 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5519 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5520 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5521 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander Diagnosis and Correction Revised Wheel Bearing: All Technical Service Bulletins Steering Wander - Diagnosis and Correction Revised NUMBER: 19-07-00 GROUP: Steering DATE: September 22, 2000 SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering wander. MODELS: 1998-2001 (AB) Ram Van/Wagon SYMPTOM/CONDITION: Steering Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering wander can be created by a number of different conditions including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying extra added weight (e.g. tool boxes). ^ Steering and/or suspension components that are worn or damaged. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: UNDER CERTAIN ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. DIAGNOSIS: 1. Verify that the vehicle is not equipped with non-factory installed options or equipment that may cause the vehicle to wander such as heavy toolboxes or hardware that may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended may cause the vehicle to wander and should be replaced before continuing with the diagnosis. 3. Inflate all tires to the pressure specified in the Tire Inflation Pressure sheet (located in the glove box). NOTE: TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS BUT, ONLY IF THE VEHICLE IS AT CURB OR LIGHT LOAD CONDITIONS. 4. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without cross wind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Proceed to the next step if the vehicle exhibits a steering wander condition. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-3 OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, ETC.). 5. Raise the vehicle on an appropriate lift. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander Diagnosis and Correction Revised > Page 5526 6. Secure a dial indicator to the lower control arm. Position the dial indicator so that the tip of the indicator contacts the inside face of the rotor (Figure 1). 7. Place your hands at the top and bottom of the tire/wheel assembly and push the tire/wheel assembly inboard (Figure 2). Zero the dial indicator. With your hands at the top and bottom of the tire/wheel assembly, pull the tire/wheel assembly outboard (Figure 3). Record the dial indicator reading. Perform this procedure on both front wheel bearings and proceed to the next step if the wheel bearing endplay exceeds 0.025 - 0.076 mm (0.001 - 0.003 in.). Proceed to Step 9 if wheel-bearing endplay on both front wheel bearings are within specifications. NOTE: WHEEL BEARING INSPECTION AND ADJUSTMENT IS ONLY REQUIRED ON WHEEL BEARINGS EXCEEDING 0.025 - 0.076 MM (0.001 - 0.003 IN.) ENDPLAY. 8. Remove the wheel bearing protective end cap, cotter pin, nut lock, nut, and washer from the spindle. Inspect the wheel bearings. If it is determined that wheel bearing replacement is necessary, refer to the appropriate Ram Van/Wagon Service Manual, Group 02, Wheel Bearings, for removal and installation information. Reinstall the wheel bearings, washer, and adjustment nut if the wheel bearings pass the inspection. 9. Using a torque wrench, tighten the wheel bearing adjustment nut to 54 N.m (40 ft. lbs.) while rotating the tire/wheel assembly. Stop the wheel from rotating and loosen the nut. Using the procedure identified in Steps 6 and 7 to measure endplay, adjust the front wheel bearing endplay until 0.025 - 0.076 mm (0.001 - 0.003 in.) endplay has been achieved. Install the nut lock and a new cotter pin. 10. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual. Any worn steering and/or suspension component must be replaced prior to performing an alignment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander Diagnosis and Correction Revised > Page 5527 11. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the chart for proper alignment specifications. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander Diagnosis and Correction Revised Wheel Bearing: All Technical Service Bulletins Steering Wander - Diagnosis and Correction Revised NUMBER: 19-07-00 GROUP: Steering DATE: September 22, 2000 SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering wander. MODELS: 1998-2001 (AB) Ram Van/Wagon SYMPTOM/CONDITION: Steering Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering wander can be created by a number of different conditions including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying extra added weight (e.g. tool boxes). ^ Steering and/or suspension components that are worn or damaged. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: UNDER CERTAIN ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. DIAGNOSIS: 1. Verify that the vehicle is not equipped with non-factory installed options or equipment that may cause the vehicle to wander such as heavy toolboxes or hardware that may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended may cause the vehicle to wander and should be replaced before continuing with the diagnosis. 3. Inflate all tires to the pressure specified in the Tire Inflation Pressure sheet (located in the glove box). NOTE: TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS BUT, ONLY IF THE VEHICLE IS AT CURB OR LIGHT LOAD CONDITIONS. 4. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without cross wind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Proceed to the next step if the vehicle exhibits a steering wander condition. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-3 OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, ETC.). 5. Raise the vehicle on an appropriate lift. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander Diagnosis and Correction Revised > Page 5533 6. Secure a dial indicator to the lower control arm. Position the dial indicator so that the tip of the indicator contacts the inside face of the rotor (Figure 1). 7. Place your hands at the top and bottom of the tire/wheel assembly and push the tire/wheel assembly inboard (Figure 2). Zero the dial indicator. With your hands at the top and bottom of the tire/wheel assembly, pull the tire/wheel assembly outboard (Figure 3). Record the dial indicator reading. Perform this procedure on both front wheel bearings and proceed to the next step if the wheel bearing endplay exceeds 0.025 - 0.076 mm (0.001 - 0.003 in.). Proceed to Step 9 if wheel-bearing endplay on both front wheel bearings are within specifications. NOTE: WHEEL BEARING INSPECTION AND ADJUSTMENT IS ONLY REQUIRED ON WHEEL BEARINGS EXCEEDING 0.025 - 0.076 MM (0.001 - 0.003 IN.) ENDPLAY. 8. Remove the wheel bearing protective end cap, cotter pin, nut lock, nut, and washer from the spindle. Inspect the wheel bearings. If it is determined that wheel bearing replacement is necessary, refer to the appropriate Ram Van/Wagon Service Manual, Group 02, Wheel Bearings, for removal and installation information. Reinstall the wheel bearings, washer, and adjustment nut if the wheel bearings pass the inspection. 9. Using a torque wrench, tighten the wheel bearing adjustment nut to 54 N.m (40 ft. lbs.) while rotating the tire/wheel assembly. Stop the wheel from rotating and loosen the nut. Using the procedure identified in Steps 6 and 7 to measure endplay, adjust the front wheel bearing endplay until 0.025 - 0.076 mm (0.001 - 0.003 in.) endplay has been achieved. Install the nut lock and a new cotter pin. 10. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual. Any worn steering and/or suspension component must be replaced prior to performing an alignment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander Diagnosis and Correction Revised > Page 5534 11. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the chart for proper alignment specifications. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Page 5535 Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front REMOVAL 1. Lock brake pedal in up position. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 4. Remove disc brake caliper. 5. Remove the dust cap, cotter pin, and remaining hub components from spindle. 6. Carefully slide the hub/rotor from spindle. CAUTION: Use care to prevent inner wheel bearing and seal from contacting spindle threads during removal). 7. Remove the seal and inner wheel bearing from the hub/rotor. Remove the inner bearing races from hub/rotor with a pin punch. INSTALLATION 1. Install the new bearing cup(s) with an appropriate installation tool. 2. Apply a coating of Mopar (R) Wheel Bearing Grease to inner surface area of hub. Install inner wheel bearing and new bearing seal. 3. Inspect bearing and seal contact surfaces on spindle for burrs and or roughness. 4. Remove all rough contact surfaces from spindle. Apply a coating of lubricant. CAUTION: Use care to prevent inner wheel bearing and seal from contacting spindle threads during installation. 5. Carefully slide the hub/rotor onto spindle. Install outer wheel bearing, washer and retaining nut. 6. Tighten the nut to 41 - 54 Nm (30 - 40 ft. lbs.) to preload bearing while rotating the hub/rotor. Stop hub/rotor and loosen nut to completely release bearing preload torque. Tighten the nut finger-tight and install the nut lock. Install a new cotter pin. 7. The adjustment (above) should have 0.254 - 0.0762 mm (0.001 - 0.003 inch) end play. 8. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. 9. Install disc brake caliper. 10. Install the wheel and tire assembly and lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5538 Wheel Bearing: Service and Repair Rear 8 1/4 and 9 1/4 Axles REMOVAL 1. Remove axle shaft. Axle Seal Removal 2. Remove axle shaft seal from the end of the axle tube with a small pry bar. NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. Axle Shaft Bearing Removal Tool 3. Remove the axle shaft bearing from the axle tube with Bearing Removal Tool Set 6310, using Adapter Foot 6310-9. INSTALLATION NOTE: Do not install the original axle shaft seal. Always install a new seal. 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5539 Axle Shaft Seal And Bearing Installation 2. Install the axle shaft bearing with Installer C-4198 and Handle C-4171. Ensure that the bearing part number is against the installer. Verify that the bearing in installed straight and the tool fully contacts the axle tube when seating the bearing. 3. Install a new axle seal with Installer C-4076-B and Handle C-4735-1. When the tool contacts the axle tube, the seal is installed to the correct depth. 4. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 5. Install the axle shaft. With 9 1/4 Axle REMOVAL 1. Remove axle shaft. Axle Seal Removal 2. Remove axle shaft seal from the end of the axle tube with a small pry bar. Axle Shaft Bearing Removal Tool Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5540 3. Remove the axle shaft bearing from the axle tube with Bearing Removal Tool C-4828. INSTALLATION NOTE: Do not install the original axle shaft seal. Always install a new seal. 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. Axle Shaft Seal And Bearing Installation 2. Install the axle shaft bearing with Installer C-4826-1 and Handle C-4171. Ensure that the bearing part number is against the installer. Verify that the bearing in installed straight and the tool fully contacts the axle tube when seating the bearing. 3. Install a new axle seal with Installer C-4826-1, Adapter C-4826-2, and Handle C-4171. When the tool contacts the axle tube, the seal is installed to the correct depth. 4. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 5. Install the axle shaft. 248 RBI Axle REMOVAL 1. Remove wheel and tire assembly. 2. Remove brake drum. 3. Remove the axle shaft. 4. Remove the lock wedge and adjustment nut. Use Socket DD-1241-JD to remove the adjustment nut. 5. Remove the hub assembly. The outer axle bearing will slide out as the hub is being removed. 6. Remove inner grease seal and discard. Use Installer 5064 and Handle C-4171 to drive grease seal and inner axle bearing from the hub. 7. Remove the bearing cups from the hub bore. Use a brass drift, or an appropriate removal tool, to tap out the cups. INSTALLATION 1. Thoroughly clean both axle bearings and interior of the hub with an appropriate cleaning solvent. 2. Install the bearing cups. Use Installer 8151 and Handle C-4171 to install the bearing cups. 3. Apply lubricant to surface area of the bearing cup. 4. Install the inner axle bearing in the hub. 5. Install a new bearing grease seal. Use Installer 8149 and Handle C-4171 to install the grease seal. 6. Inspect the bearing and seal contact surfaces on the axle tube spindle for burrs and/or roughness. Remove all the rough contact surfaces from the axle spindle. Apply a coating of multi-purpose NLGI, grade 2, EP-type lubricant to the axle. CAUTION: Use care to prevent the bearing grease seal from contacting the axle tube spindle threads during installation. Otherwise, the seal could be damaged. 7. Carefully slide the hub onto the axle. 8. Install the outer axle bearing. 9. Install the hub bearing adjustment nut. Use Socket DD-1241-JD to install the adjustment nut. 10. Tighten the adjustment nut to 163-190 Nm (120-140 ft. lbs.) while rotating the wheel. 11. Loosen the adjustment nut 1/8 of-a-turn to provide 0.001-inch to 0.010-inch wheel bearing end play. 12. Tap the locking wedge into the spindle keyway and adjustment nut. Try to ensure that the locking wedge is installed into a new position in the adjustment nut. 13. Install the axle shaft. 14. Install the brake drum. 15. Install the wheel and tire assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation The temporary spare tire is designed for emergency use only. The original tire should be repaired and reinstalled at the first opportunity, or replaced with a new. Do not exceed speeds of 50 MPH when the temporary spare tire is in use on the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5554 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5555 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5556 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5562 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5563 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5564 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5565 Wheels: Description and Operation The rim size is on the safety certification label located on the drivers door shut face. The size of the rim is determined by the drivetrain package. Original equipment wheels are designed for operation up to the specified maximum vehicle capacity. Fig. 1 All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the wheel. The wheel studs and nuts are designed for specific applications. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Do not use replacement studs or nuts with a different design or lesser quality. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5566 Wheels: Testing and Inspection Inspect wheels for: - Excessive run out - Dents or cracks - Damaged wheel lug nut holes - Air leaks from any area or surface of the rim NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. Used wheels are not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5567 Wheels: Service and Repair REPLACEMENT NOTES: Wheels must be replaced if they have: Excessive runout - Bent or dented - Leak air through welds - Have damaged bolt holes Wheel repairs employing hammering, heating, or welding are not allowed. Original equipment wheels are available through your dealer. Replacement wheels from any other source should be equivalent in: Load carrying capacity - Diameter - Width - Offset - Mounting configuration Failure to use equivalent replacement wheels may affect the safety and handling of your vehicle. Replacement with used wheels is not recommended. Their service history may have included severe treatment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5576 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5577 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5578 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair Technical Service Bulletin # 19-002-01A Date: 010928 Steering/Suspension - Wander Diagnosis/Repair NUMBER: 19-002-01 REV. A GROUP: Steering DATE: Sept. 28, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-01, DATED SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity. MODELS: 1998 - 2001 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES. SYMPTOM/CONDITION: Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering sensitivity/wander can be attributed to a number of different conditions, including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket tires and wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR). ^ Steering and/or suspension components that are worn, damaged or out of adjustment. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5584 PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Diagnosis/Repair Procedures 1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the front suspension components including wheel bearings, for any signs of wear or damage. Make any repairs necessary. NOTE: MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO PROCEEDING. 3. Lubricate all front steering and suspension system components. 4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before continuing with the diagnosis. 5. Inflate the tires to 65 psi. - front and 80 psi. - rear NOTE: -IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER, HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS REQUIRED TO CORRECT THE CONDITION. 6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the steering wander condition has been repaired. If the vehicle still exhibits a steering wander condition, proceed to the steering gear replacement procedure. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD CROWN, GROOVED ROADS, ETC.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5585 ^ WHEEL BEARING ADJUSTMENT 1. Verify the front wheel bearing end play. If the end play is above the specification, complete the following repair procedure NOTE: The end play should be 0.25-0.076 mm (0.001-0.003 in.). 2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter pin. 3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. STEERING GEAR REPLACEMENT NOTE: INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER. IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR 52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE 16-13 :1 VARIABLE RATIO GEAR. 1. Using the procedures outlined in the appropriate service manual, remove the steering gear and install the new steering gear, P/N 52013456AA. NOTE: MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL. ^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY) NOTE: THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES. INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB. GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT. CAUTION: THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE TO AVOID BENDING THE SIDE RAIL FLANGE. 1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It the part numbers on the components differ from these numbers, they must be replaced. 2. Using the procedures outlined in the appropriate service manual, remove the rear springs and shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n **52106320A0 ** WHEEL ALIGNMENT NOTE: IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5586 3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any worn steering and/or suspension component must be replaced prior to performing an alignment. 4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the following chart for proper alignment specifications. NOTE: FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM, ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. CAUTION: ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander Diagnosis and Correction Revised Wheel Bearing: All Technical Service Bulletins Steering Wander - Diagnosis and Correction Revised NUMBER: 19-07-00 GROUP: Steering DATE: September 22, 2000 SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering wander. MODELS: 1998-2001 (AB) Ram Van/Wagon SYMPTOM/CONDITION: Steering Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering wander can be created by a number of different conditions including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying extra added weight (e.g. tool boxes). ^ Steering and/or suspension components that are worn or damaged. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: UNDER CERTAIN ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. DIAGNOSIS: 1. Verify that the vehicle is not equipped with non-factory installed options or equipment that may cause the vehicle to wander such as heavy toolboxes or hardware that may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended may cause the vehicle to wander and should be replaced before continuing with the diagnosis. 3. Inflate all tires to the pressure specified in the Tire Inflation Pressure sheet (located in the glove box). NOTE: TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS BUT, ONLY IF THE VEHICLE IS AT CURB OR LIGHT LOAD CONDITIONS. 4. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without cross wind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Proceed to the next step if the vehicle exhibits a steering wander condition. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-3 OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, ETC.). 5. Raise the vehicle on an appropriate lift. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander Diagnosis and Correction Revised > Page 5591 6. Secure a dial indicator to the lower control arm. Position the dial indicator so that the tip of the indicator contacts the inside face of the rotor (Figure 1). 7. Place your hands at the top and bottom of the tire/wheel assembly and push the tire/wheel assembly inboard (Figure 2). Zero the dial indicator. With your hands at the top and bottom of the tire/wheel assembly, pull the tire/wheel assembly outboard (Figure 3). Record the dial indicator reading. Perform this procedure on both front wheel bearings and proceed to the next step if the wheel bearing endplay exceeds 0.025 - 0.076 mm (0.001 - 0.003 in.). Proceed to Step 9 if wheel-bearing endplay on both front wheel bearings are within specifications. NOTE: WHEEL BEARING INSPECTION AND ADJUSTMENT IS ONLY REQUIRED ON WHEEL BEARINGS EXCEEDING 0.025 - 0.076 MM (0.001 - 0.003 IN.) ENDPLAY. 8. Remove the wheel bearing protective end cap, cotter pin, nut lock, nut, and washer from the spindle. Inspect the wheel bearings. If it is determined that wheel bearing replacement is necessary, refer to the appropriate Ram Van/Wagon Service Manual, Group 02, Wheel Bearings, for removal and installation information. Reinstall the wheel bearings, washer, and adjustment nut if the wheel bearings pass the inspection. 9. Using a torque wrench, tighten the wheel bearing adjustment nut to 54 N.m (40 ft. lbs.) while rotating the tire/wheel assembly. Stop the wheel from rotating and loosen the nut. Using the procedure identified in Steps 6 and 7 to measure endplay, adjust the front wheel bearing endplay until 0.025 - 0.076 mm (0.001 - 0.003 in.) endplay has been achieved. Install the nut lock and a new cotter pin. 10. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual. Any worn steering and/or suspension component must be replaced prior to performing an alignment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander Diagnosis and Correction Revised > Page 5592 11. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the chart for proper alignment specifications. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander Diagnosis and Correction Revised Wheel Bearing: All Technical Service Bulletins Steering Wander - Diagnosis and Correction Revised NUMBER: 19-07-00 GROUP: Steering DATE: September 22, 2000 SUBJECT: Steering Wander Diagnosis OVERVIEW: This bulletin provides a diagnostic procedure for steering wander. MODELS: 1998-2001 (AB) Ram Van/Wagon SYMPTOM/CONDITION: Steering Wander Diagnosis is the diagnosis of a condition where slight steering corrections are necessary to be able to keep the vehicle moving in a straight line. Steering wander can be created by a number of different conditions including but not limited to the following: ^ Non-factory installed options. ^ Tires or wheels of different size. ^ Aftermarket wheels. ^ Tires that have a belt that has shifted. ^ Incorrect tire pressure. ^ A vehicle that is carrying extra added weight (e.g. tool boxes). ^ Steering and/or suspension components that are worn or damaged. ^ Wheel bearings that are loose, worn, or damaged. ^ A vehicle that is not within alignment specifications. NOTE: UNDER CERTAIN ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER. The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering system components are functioning as designed and are not the root cause of steering wander. DIAGNOSIS: 1. Verify that the vehicle is not equipped with non-factory installed options or equipment that may cause the vehicle to wander such as heavy toolboxes or hardware that may cause the vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR). 2. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged and/or wheels that are of a different size and/or offset than recommended may cause the vehicle to wander and should be replaced before continuing with the diagnosis. 3. Inflate all tires to the pressure specified in the Tire Inflation Pressure sheet (located in the glove box). NOTE: TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS BUT, ONLY IF THE VEHICLE IS AT CURB OR LIGHT LOAD CONDITIONS. 4. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70 mph), preferably without cross wind conditions. If crosswind conditions are prevalent, drive the vehicle in both directions relative to the crosswind. Proceed to the next step if the vehicle exhibits a steering wander condition. NOTE: VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-3 OR THE CONDITION MAY HAVE BEEN CAUSED BY ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, ETC.). 5. Raise the vehicle on an appropriate lift. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander Diagnosis and Correction Revised > Page 5598 6. Secure a dial indicator to the lower control arm. Position the dial indicator so that the tip of the indicator contacts the inside face of the rotor (Figure 1). 7. Place your hands at the top and bottom of the tire/wheel assembly and push the tire/wheel assembly inboard (Figure 2). Zero the dial indicator. With your hands at the top and bottom of the tire/wheel assembly, pull the tire/wheel assembly outboard (Figure 3). Record the dial indicator reading. Perform this procedure on both front wheel bearings and proceed to the next step if the wheel bearing endplay exceeds 0.025 - 0.076 mm (0.001 - 0.003 in.). Proceed to Step 9 if wheel-bearing endplay on both front wheel bearings are within specifications. NOTE: WHEEL BEARING INSPECTION AND ADJUSTMENT IS ONLY REQUIRED ON WHEEL BEARINGS EXCEEDING 0.025 - 0.076 MM (0.001 - 0.003 IN.) ENDPLAY. 8. Remove the wheel bearing protective end cap, cotter pin, nut lock, nut, and washer from the spindle. Inspect the wheel bearings. If it is determined that wheel bearing replacement is necessary, refer to the appropriate Ram Van/Wagon Service Manual, Group 02, Wheel Bearings, for removal and installation information. Reinstall the wheel bearings, washer, and adjustment nut if the wheel bearings pass the inspection. 9. Using a torque wrench, tighten the wheel bearing adjustment nut to 54 N.m (40 ft. lbs.) while rotating the tire/wheel assembly. Stop the wheel from rotating and loosen the nut. Using the procedure identified in Steps 6 and 7 to measure endplay, adjust the front wheel bearing endplay until 0.025 - 0.076 mm (0.001 - 0.003 in.) endplay has been achieved. Install the nut lock and a new cotter pin. 10. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the appropriate Ram Van/Wagon Service Manual. Any worn steering and/or suspension component must be replaced prior to performing an alignment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander Diagnosis and Correction Revised > Page 5599 11. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate Ram Van/Wagon Service Manual, Group 02, Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications. Refer to the chart for proper alignment specifications. NOTE: THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM VAN/WAGONS. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 5600 Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front REMOVAL 1. Lock brake pedal in up position. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 4. Remove disc brake caliper. 5. Remove the dust cap, cotter pin, and remaining hub components from spindle. 6. Carefully slide the hub/rotor from spindle. CAUTION: Use care to prevent inner wheel bearing and seal from contacting spindle threads during removal). 7. Remove the seal and inner wheel bearing from the hub/rotor. Remove the inner bearing races from hub/rotor with a pin punch. INSTALLATION 1. Install the new bearing cup(s) with an appropriate installation tool. 2. Apply a coating of Mopar (R) Wheel Bearing Grease to inner surface area of hub. Install inner wheel bearing and new bearing seal. 3. Inspect bearing and seal contact surfaces on spindle for burrs and or roughness. 4. Remove all rough contact surfaces from spindle. Apply a coating of lubricant. CAUTION: Use care to prevent inner wheel bearing and seal from contacting spindle threads during installation. 5. Carefully slide the hub/rotor onto spindle. Install outer wheel bearing, washer and retaining nut. 6. Tighten the nut to 41 - 54 Nm (30 - 40 ft. lbs.) to preload bearing while rotating the hub/rotor. Stop hub/rotor and loosen nut to completely release bearing preload torque. Tighten the nut finger-tight and install the nut lock. Install a new cotter pin. 7. The adjustment (above) should have 0.254 - 0.0762 mm (0.001 - 0.003 inch) end play. 8. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. 9. Install disc brake caliper. 10. Install the wheel and tire assembly and lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5603 Wheel Bearing: Service and Repair Rear 8 1/4 and 9 1/4 Axles REMOVAL 1. Remove axle shaft. Axle Seal Removal 2. Remove axle shaft seal from the end of the axle tube with a small pry bar. NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. Axle Shaft Bearing Removal Tool 3. Remove the axle shaft bearing from the axle tube with Bearing Removal Tool Set 6310, using Adapter Foot 6310-9. INSTALLATION NOTE: Do not install the original axle shaft seal. Always install a new seal. 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5604 Axle Shaft Seal And Bearing Installation 2. Install the axle shaft bearing with Installer C-4198 and Handle C-4171. Ensure that the bearing part number is against the installer. Verify that the bearing in installed straight and the tool fully contacts the axle tube when seating the bearing. 3. Install a new axle seal with Installer C-4076-B and Handle C-4735-1. When the tool contacts the axle tube, the seal is installed to the correct depth. 4. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 5. Install the axle shaft. With 9 1/4 Axle REMOVAL 1. Remove axle shaft. Axle Seal Removal 2. Remove axle shaft seal from the end of the axle tube with a small pry bar. Axle Shaft Bearing Removal Tool Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5605 3. Remove the axle shaft bearing from the axle tube with Bearing Removal Tool C-4828. INSTALLATION NOTE: Do not install the original axle shaft seal. Always install a new seal. 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. Axle Shaft Seal And Bearing Installation 2. Install the axle shaft bearing with Installer C-4826-1 and Handle C-4171. Ensure that the bearing part number is against the installer. Verify that the bearing in installed straight and the tool fully contacts the axle tube when seating the bearing. 3. Install a new axle seal with Installer C-4826-1, Adapter C-4826-2, and Handle C-4171. When the tool contacts the axle tube, the seal is installed to the correct depth. 4. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 5. Install the axle shaft. 248 RBI Axle REMOVAL 1. Remove wheel and tire assembly. 2. Remove brake drum. 3. Remove the axle shaft. 4. Remove the lock wedge and adjustment nut. Use Socket DD-1241-JD to remove the adjustment nut. 5. Remove the hub assembly. The outer axle bearing will slide out as the hub is being removed. 6. Remove inner grease seal and discard. Use Installer 5064 and Handle C-4171 to drive grease seal and inner axle bearing from the hub. 7. Remove the bearing cups from the hub bore. Use a brass drift, or an appropriate removal tool, to tap out the cups. INSTALLATION 1. Thoroughly clean both axle bearings and interior of the hub with an appropriate cleaning solvent. 2. Install the bearing cups. Use Installer 8151 and Handle C-4171 to install the bearing cups. 3. Apply lubricant to surface area of the bearing cup. 4. Install the inner axle bearing in the hub. 5. Install a new bearing grease seal. Use Installer 8149 and Handle C-4171 to install the grease seal. 6. Inspect the bearing and seal contact surfaces on the axle tube spindle for burrs and/or roughness. Remove all the rough contact surfaces from the axle spindle. Apply a coating of multi-purpose NLGI, grade 2, EP-type lubricant to the axle. CAUTION: Use care to prevent the bearing grease seal from contacting the axle tube spindle threads during installation. Otherwise, the seal could be damaged. 7. Carefully slide the hub onto the axle. 8. Install the outer axle bearing. 9. Install the hub bearing adjustment nut. Use Socket DD-1241-JD to install the adjustment nut. 10. Tighten the adjustment nut to 163-190 Nm (120-140 ft. lbs.) while rotating the wheel. 11. Loosen the adjustment nut 1/8 of-a-turn to provide 0.001-inch to 0.010-inch wheel bearing end play. 12. Tap the locking wedge into the spindle keyway and adjustment nut. Try to ensure that the locking wedge is installed into a new position in the adjustment nut. 13. Install the axle shaft. 14. Install the brake drum. 15. Install the wheel and tire assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Wheel Torque Sequence - Master Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 5610 Wheel Fastener: Specifications Lug Nut Torque 15 Inch 5 Stud Wheel ........................................................................................................................................................... 109 - 150 Nm (80 - 110 ft. lbs.) 16 Inch 8 Stud Wheel ......................................................................................................................................................... 163 - 203 Nm (120 - 150 ft. lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 5611 Wheel Fastener: Service and Repair REMOVAL 1. Remove wheel and tire assembly. 2. Remove disc brake rotor. 3. Place rotor on flat surface and drive studs out of the with a hammer and punch. INSTALLATION 1. Turn the rotor over and place in a vise. 2. Drive new studs into the rotor with hammer and punch. 3. Install rotor. 4. Install wheel and tire assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation Air Door Actuator / Motor: Description and Operation SYSTEM OPERATION Blend-Air Door Motor The blend-air door on heater-only and heater-A/C models is connected with a short mechanical link to an electronic blend-air door actuator motor. The blend-air door motor controls the positioning of the blend-air door in the heater-A/C housing. The blend- air door motor is mounted to the top of the right end of the distribution duct under the instrument panel in the passenger compartment. A mechanical link is attached to the end of the blend-air door motor lever in the passenger compartment and passes through a bellows-type boot and a small hole in the dash panel to the engine compartment. In the engine compartment, the link is attached to the end of the blend air door lever on the top cover of the heater-A/C housing. The blend-air door motor is controlled by a potentiometer that is integral to the heater-only or heater-A/C control. The rotary-type temperature control knob positions the potentiometer, and the potentiometer controls the voltage to the blend-air door motor. The blend-air door motor moves the blend-air door based upon the voltage level of the signal received from the potentiometer. The blend-air door motor is accessible for service through the instrument panel glove box opening. The blend-air door motor cannot be repaired and, if faulty or damaged, it must be replaced. The mechanical link and boot are available for service replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Page 5617 Air Door Actuator / Motor: Testing and Inspection The blend-air door in the heater-A/C housing is controlled by a combination of mechanical linkage and electronic controls. The mechanical linkage is connected to the blend-air door pivot shaft lever in the engine compartment on one end, and to the blend-air door servo motor lever in the passenger compartment on the other end. The blend-air door motor is controlled by the temperature control knob through a potentiometer that is integral to the heater-only or heater-A/C control assembly. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR-BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Roll down the glove box from the instrument panel. Refer to Glove Box - Roll Down in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel Systems for the procedures. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Look through the instrument panel glove box opening to locate the blend-air door motor on the top of the distribution duct. Check that the blend-air door link is connected to the blend-air door motor lever. If OK, go to Step 6. If not OK, see Blend-Air Door Motor in the Removal and Installation. 5. While observing the blend-air door motor, slowly rotate the temperature control knob from stop to stop. The motor lever movement should correspond to the movements of the temperature control knob. If OK, check the blend-air door in the heater-A/C housing for damage. If not OK, go to Step 7. 6. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the blend-air door motor. Check for continuity between the blend air door driver circuit cavity of the blend-air door motor wire harness connector and a good ground. There should be continuity. If OK, go to Step 8. If not OK, repair the open circuit to ground as required. 7. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the ignition feed circuit cavity of the blend-air door motor wire harness connector. If OK, go to Step 9. If not OK, repair the open circuit to the junction block fuse as required. 8. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check the resistance between the blend air door driver circuit cavity and the ignition feed circuit cavity of the blend-air door motor wire harness connector. The resistance should be from 8.5 to 11.5 kilohms. If OK, go to Step 10. If not OK, go to Step 13. 9. Move the temperature control knob to the full counterclockwise (Cool) position. Measure the resistance between the ignition feed circuit cavity and the blend door feedback signal circuit cavity of the blend-air door motor wire harness connector. The resistance should not be more than 100 ohms. If OK, go to Step 11. If not OK, go to Step 13. 10. Move the temperature control knob to the full clockwise (Warm) position. Measure the resistance between the ignition feed circuit cavity and the blend door feedback signal circuit cavity of the blend-air door motor wire harness connector. The resistance should be less than 10 ohms. If OK, go to Step 12. If not OK, go to Step 13. 11. Measure the resistance between the ignition feed circuit cavity and the blend door feedback signal circuit cavity of the blend-air door motor wire harness connector while slowly rotating the temperature control knob from stop to stop. There should be no spikes greater than 11.5 kilohms. If OK, replace the faulty blend-air door motor. If not OK, replace the faulty heater-only or heater-A/C control unit. 12. Remove the heater-only or heater-A/C control from the instrument panel. See Heater-A/C Control Replacement for the procedures. Check for continuity between the blend air door driver circuit cavity of the blend-air controller wire harness connector and a good ground. There should be continuity. If OK, go to Step 14. If not OK, repair the open circuit to ground as required. 13. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the ignition feed circuit cavity of the blend-air controller wire harness connector. If OK, go to Step 15. If not OK, repair the open circuit to the junction block fuse as required. 14. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check the resistance between the blend air door driver circuit terminal and the ignition feed circuit terminal in the blend-air controller receptacle on the back of the heater-A/C control. The resistance should be from 8.5 to 11.5 kilohms. If OK, go to Step 16. If not OK, replace the faulty heater-A/C control unit. 15. Move the temperature control knob to the full counterclockwise (Cool) position. Measure the resistance between the ignition feed circuit terminal and the blend door feedback signal circuit terminal in the blend-air controller receptacle on the back of the heater-A/C control. The resistance should not be more than 100 ohms. If OK, go to Step 17. If not OK, replace the faulty heater-A/C control unit. 16. Move the temperature control knob to the full clockwise (Warm) position. Measure the resistance between the ignition feed circuit terminal and the blend door feedback signal circuit terminal in the blend-air controller receptacle on the back of the heater-A/C control. The resistance should be less than 10 ohms. If OK, repair the blend door feedback signal circuit to the blend-air door motor as required. If not OK, replace the faulty heater-A/C control unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement Air Door Actuator / Motor: Service and Repair Blend Door Actuator Replacement WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAGS DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. 3. Reach through the instrument panel glove box opening to access and unplug the wire harness connector from the blend-air door motor. Blend-Air Door Motor Remove/Install 4. Reach through the instrument panel glove box opening to unlatch the link retainer on the end of the blend-air door motor lever. Remove the link from the retainer. 5. Remove the three screws that secure the blend-air door motor to the top of the distribution duct. 6. Remove the blend-air door motor from the distribution duct. INSTALLATION 1. Position the blend-air door motor on the top of the distribution duct. 2. Secure the blend-air door motor to the distribution duct with three screws. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Blend-Air Door Linkage 3. Install the link to the retainer on the end of the blend-air door lever. Be certain that the retainer is positioned between the two sets of nubs on the link, then snap the retainer closed. 4. Plug in the blend-air door motor wire harness connector. 5. Reinstall the glove box in the instrument panel. 6. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 5620 Air Door Actuator / Motor: Service and Repair Mode Door Actuator Replacement WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL Recirculation Air Door Actuator WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Disconnect and isolate the battery negative cable. 2. if the vehicle is not equipped with air conditioning, go to Step 5. if the vehicle is equipped with air conditioning, disconnect the suction line jumper at the expansion valve. 3. Remove the screws that secure the filter-drier and its mounting bracket to the heater-A/C housing and the cowl side panel. Swing the filter-drier, mounting bracket and refrigerant plumbing as a unit out of the way towards the center of the vehicle. Recirculation Air Door Actuator Remove/Install 4. Unplug the vacuum harness connector from the recirculation air door actuator located on the top of the recirculation housing near the cowl side panel in the engine compartment. 5. Unsnap the retaining clip that secures the recirculation air door actuator link to the recirculation air door lever. 6. Loosen the two nuts that secure the recirculation air door actuator to the bracket molded into the upper forward edge of the recirculation housing. 7. Disengage the actuator link from the recirculation air door lever. 8. Lift the recirculation air door actuator upwards far enough to disengage the two mounting studs from the slotted holes in the molded bracket on the upper forward edge of the recirculation housing. 9. Remove the recirculation air door actuator from the engine compartment. 10. Reverse the removal procedures to install. Tighten the mounting nuts to 2.2 N.m (20 in. lbs.). Floor-defrost Door Actuator 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the vehicle. Refer to: "Instrument Panel Gauges and Warning Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair Floor-Defrost Door Actuator 3. Unplug the two vacuum harness connectors from the floor-defrost door actuator located on a mount between the two defroster outlets on the left Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 5621 side of the distribution duct. Vacuum Actuator Remove/Install - Typical 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the actuator latch while pulling firmly upward on the actuator to remove the actuator from the mount on the distribution duct. 5. Lift the actuator upward until the actuator link is almost parallel with the floor-defrost door lever, then disengage the hole on the end of the link from the pin on the end of the lever. 6. Remove the floor-defrost door actuator from the distribution duct. 7. Reverse the removal procedures to install. Floor-panel Door Actuator 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the vehicle. Refer to: "Instrument Panel Gauges and Warning Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair Floor-panel Door Actuator 3. Unplug the two vacuum harness connectors from the floor-panel door actuator located on a mount outboard of the demister outlet on the right side of the distribution duct. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 5622 Recirculation Air Door Remove/Install 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the actuator latch while pulling firmly outward on the actuator to remove the actuator from the mount on the distribution duct. 5. Swing the actuator around the floor-panel door lever about 1800, or until the actuator link is at almost a right angle on the opposite side of the lever, then disengage the hole on the end of the link from the pin on the end of the lever. 6. Remove the floor-panel door actuator from the distribution duct. 7. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 5623 Air Door Actuator / Motor: Service and Repair Rear Heat A/C The rear mode control motor is used only on models with the optional rear heater-A/C unit. The rear mode control motor can be removed without removing the rear heater-A/C unit from the vehicle. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the rear heater-A/C unit. 3. Remove the vertical duct from the rear heater- A/C unit. 4. Remove the horizontal duct from the rear heater-A/C unit. Rear Mode Control Motor Remove/Install 5. Unplug the wire harness connector from the rear mode control motor, located on the outboard side of the upper housing near the front of the rear heater-A/C unit. 6. Remove the three screws that secure the rear mode control motor to the rear heater-A/C unit upper housing. 7. Move the rear mode control motor outboard far enough to disengage the motor hub from the water valve control cable adaptor. 8. Remove the rear mode control motor from the rear heater-A/C unit. INSTALLATION 1. Install the rear mode control motor hub over the water valve control cable adaptor. Be certain to index the flats in the motor hub to the flats on the adaptor. 2. Install three screws to secure the rear mode control motor to the mounting bosses on the rear heater-A/C unit upper housing. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 3. Plug in the wire harness connector to the rear mode control motor. 4. Reinstall the horizontal duct to the rear heater-A/C unit. 5. Reinstall the vertical duct on the rear heater-A/C unit. 6. Reinstall the cover on the rear heater-A/C unit. 7. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Distribution Duct Replacement Air Duct: Service and Repair Distribution Duct Replacement The distribution duct can be removed from the vehicle without disconnecting the refrigerant lines or discharging the refrigerant system. The distribution duct assembly must be removed from the vehicle and disassembled for service access of the floor-defrost door or the floor-panel door. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIR BAG SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel Assembly Replacement. 3. Remove the blend-air door motor from the distribution duct. See Blend-Air Door Motor Replacement procedures. 4. Unplug the two vacuum harness connections from each of the two vacuum actuators on the upper half of the distribution duct. 5. Remove the one screw that secures the vacuum harness retaining strap to the left end of the distribution duct. 6. Remove the vacuum harness from the distribution duct. Distribution Duct Remove/Install 7. Remove the one screw that secures the left floor outlet of the distribution duct to the instrument panel support on the left side of the dash panel engine housing extension. 8. Remove the five screws that secure the distribution duct to the dash panel. 9. Remove the distribution duct from the dash panel. Disassembly 1. Remove the seals from the inlet flange and the panel outlet flange of the distribution duct. 2. Remove the fifteen remaining screws that secure the upper half of the distribution duct to the lower half. 3. Carefully separate the two halves of the distribution duct. Inspection Examine all of the distribution duct seals for damage. Replace all damaged or deformed seals. Clean all of the upper and lower distribution duct mating flanges prior to reassembly. Inspect the distribution duct components for damage. Repair or replace any faulty or damaged components as required. Remove any foreign material or other restrictions to air flow. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Distribution Duct Replacement > Page 5628 Assembly 1. Position the upper half of the distribution duct over the lower half. Be certain that the pivot shafts for both mode doors are in their proper positions. 2. Install fifteen of the screws that secure the upper half of the distribution duct to the lower half leaving out the screw on the left rear corner of the duct that also secures the vacuum harness retaining strap. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 3. Install new seals on the inlet flange and the panel outlet flange of the distribution duct. INSTALLATION 1. Position the distribution duct to the dash panel. 2. Install the four screws that secure the distribution duct to the right side of the dash panel. Tighten the mounting screws to 2.7 N.m (24 in. lbs.). 3. Install the one screw that secures the left floor outlet of the distribution duct to the instrument panel support on the left side of the dash panel engine housing extension, and the one screw that secures the distribution duct to the dash panel between the two defroster outlets. Tighten the mounting screws to 4.5 N.m (40 in. lbs.). 4. Position and route the vacuum harness over the distribution duct. 5. Install the one screw that secures the vacuum harness retaining strap near the left end of the distribution duct. Tighten the mounting screw to 2.2 N.m (20 in. lbs.). 6. Plug in the two vacuum harness connections to each of the two vacuum actuators on the upper half of the distribution duct. 7. Reinstall the blend-air door motor to the distribution duct. See Blend-Air Door Motor Replacement. 8. Reinstall the instrument panel to the vehicle. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel Assembly Replacement. 9. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Distribution Duct Replacement > Page 5629 Air Duct: Service and Repair Duct and Outlet Replacement WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAGS DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL Outlet Barrels In addition to the panel outlet barrels in the instrument panel, models equipped with the optional rear heater-A/C unit have outlets for the rear seat passengers located in the left rear side panel lower trim and in the headliner. The service procedures for all of the instrument panel outlet barrels is the same. The outlets in the left rear side panel and in the headliner are serviced as a unit with the outlet bezels. Outlet Barrels 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry at the sides of the outlet barrels to release the snap-fit pivots on the barrel from the pivot pins in the outlet housings of the instrument panel or the instrument cluster bezel. 2. Once the outlet barrel is released from the pivots, tilt the top of the barrel out from the housing to disengage the travel limiter pin on the bottom of the barrel that is inserted into a slot in the bottom of the housing. 3. To install the outlet barrel, insert the travel limiter pin on the bottom of the barrel into the slot in the bottom of the housing. Position the top of the barrel in the outlet housing and press inward firmly and evenly on both sides of the barrel until the pivots snap into place. Outlet Housings 1. Remove the passenger side airbag module from the instrument panel. Refer to Airbag Module - Passenger Side replacement procedures. 2. Remove the barrel(s) from the outlet housing. See Ducts and Outlets - Outlet Barrels replacement procedures. Outlet Housings 3. Remove the screws that secure the outlet housing to the instrument panel. 4. Remove the outlet housing from the instrument panel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Defroster Duct Extensions 1. Remove The Instrument Panel from the passenger compartment. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel/Instrument Panel Assembly replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Distribution Duct Replacement > Page 5630 Defroster Duct Extensions 3. Remove the defroster duct extension from below the top of the instrument panel. 4. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Demister Duct Both side window demister ducts and both outboard panel ducts are integral to the demister duct unit. The inboard panel ducts are integral to the instrument panel distribution duct unit. 1. Remove the base trim from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel Base Trim replacement procedures. Demister Duct And Instrument Panel Distribution Duct 2. Remove the screws that secure the demister duct to the instrument panel armature. 3. Separate the demister duct from the instrument panel distribution duct. 4. Remove the demister duct from the instrument panel armature. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Instrument Panel Distribution Duct The inboard panel ducts are integral to the instrument panel distribution duct unit. Both side window demister ducts and both outboard panel ducts are integral to the demister duct unit. 1. Remove the base trim from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel/Instrument Panel Base Trim replacement 2. Remove the screws that secure the distribution duct to the instrument panel armature. 3. Separate the instrument panel distribution duct from the demister duct. 4. Remove the instrument panel distribution duct from the instrument panel armature. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Rear Overhead Duct A rear overhead duct is only used on models equipped with the optional rear heater-A/C unit. The rear overhead duct is integral to the rear headliner. If either the duct or the headliner is faulty or damaged, the rear headliner unit must be replaced. Rear Overhead Outlet Bezels Rear overhead outlets are only used on models equipped with the optional rear heater-A/C unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Distribution Duct Replacement > Page 5631 Rear Overhead Outlet Bezels 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter edges of the outlet bezel to release it from the overhead duct outlet. 2. Remove the overhead outlet bezel from the rear headliner. 3. To install the outlet bezel, position the bezel in the outlet opening of the rear overhead duct and press inward firmly and evenly on both sides of the bezel until it snaps into place. Rear Side Panel Outlet Bezels Rear side panel outlet bezels are only used on models equipped with the optional rear heater-A/C unit. Rear Side Panel Outlet Bezels 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry between the edge of the outlet bezel and the rear side panel lower trim panel to release the snap clips that secure the bezel to the horizontal duct. 2. Remove the outlet bezel from the rear side panel lower trim panel. 3. To install the outlet bezel, position the bezel to the holes on the horizontal duct and press inward firmly and evenly on both sides of the bezel until the retaining clips snap into place. Vertical Duct The vertical duct is only used on models equipped with the optional rear heater-A/C unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Distribution Duct Replacement > Page 5632 Rear Heater-A/C Unit Ducts Remove/Install 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry out the plug that covers the vertical duct mounting screw. 2. Loosen but do not remove the screw that secures the vertical duct to the rear side panel strainer. Only loosen the screw far enough to disengage the vertical duct from the side panel. Gently pull the vertical duct away from the rear side panel while loosening the screw so that it can be determined when the screw is disengaged from the side panel. 3. Grasp the top of the vertical duct firmly with one hand and press upward on the inboard side of the duct opening in the headliner with the other hand. Pull the top of the duct downward and inboard until it unsnaps from the headliner duct opening. 4. Lift the vertical duct off of the rear heater-A/C unit duct outlet. 5. Reverse the removal procedures to install. Tighten the mounting screw to 2.2 N.m (20 in. lbs.). Horizontal Duct The horizontal duct is only used on models equipped with the optional rear heater-A/C unit. 1. Remove the outlet bezels from the rear side panel lower trim panel. See Ducts and Outlets - Rear Side Panel Outlet Bezels replacement procedures. 2. Remove the lower trim panels from the left rear side panel. 3. Remove the two retainers that secure the horizontal duct to the left rear side panel. 4. Lift the horizontal duct off of the rear heater-A/C unit duct outlet. 5. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair Air Register: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAGS DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL Outlet Barrels In addition to the panel outlet barrels in the instrument panel, models equipped with the optional rear heater-A/C unit have outlets for the rear seat passengers located in the left rear side panel lower trim and in the headliner. The service procedures for all of the instrument panel outlet barrels is the same. The outlets in the left rear side panel and in the headliner are serviced as a unit with the outlet bezels. Outlet Barrels 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry at the sides of the outlet barrels to release the snap-fit pivots on the barrel from the pivot pins in the outlet housings of the instrument panel or the instrument cluster bezel. 2. Once the outlet barrel is released from the pivots, tilt the top of the barrel out from the housing to disengage the travel limiter pin on the bottom of the barrel that is inserted into a slot in the bottom of the housing. 3. To install the outlet barrel, insert the travel limiter pin on the bottom of the barrel into the slot in the bottom of the housing. Position the top of the barrel in the outlet housing and press inward firmly and evenly on both sides of the barrel until the pivots snap into place. Outlet Housings 1. Remove the passenger side airbag module from the instrument panel. Refer to Airbag Module - Passenger Side replacement procedures. 2. Remove the barrel(s) from the outlet housing. See Ducts and Outlets - Outlet Barrels replacement procedures. Outlet Housings 3. Remove the screws that secure the outlet housing to the instrument panel. 4. Remove the outlet housing from the instrument panel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Defroster Duct Extensions 1. Remove The Instrument Panel from the passenger compartment. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel/Instrument Panel Assembly replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Page 5636 Defroster Duct Extensions 3. Remove the defroster duct extension from below the top of the instrument panel. 4. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Demister Duct Both side window demister ducts and both outboard panel ducts are integral to the demister duct unit. The inboard panel ducts are integral to the instrument panel distribution duct unit. 1. Remove the base trim from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel Base Trim replacement procedures. Demister Duct And Instrument Panel Distribution Duct 2. Remove the screws that secure the demister duct to the instrument panel armature. 3. Separate the demister duct from the instrument panel distribution duct. 4. Remove the demister duct from the instrument panel armature. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Instrument Panel Distribution Duct The inboard panel ducts are integral to the instrument panel distribution duct unit. Both side window demister ducts and both outboard panel ducts are integral to the demister duct unit. 1. Remove the base trim from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel/Instrument Panel Base Trim replacement 2. Remove the screws that secure the distribution duct to the instrument panel armature. 3. Separate the instrument panel distribution duct from the demister duct. 4. Remove the instrument panel distribution duct from the instrument panel armature. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Rear Overhead Duct A rear overhead duct is only used on models equipped with the optional rear heater-A/C unit. The rear overhead duct is integral to the rear headliner. If either the duct or the headliner is faulty or damaged, the rear headliner unit must be replaced. Rear Overhead Outlet Bezels Rear overhead outlets are only used on models equipped with the optional rear heater-A/C unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Page 5637 Rear Overhead Outlet Bezels 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter edges of the outlet bezel to release it from the overhead duct outlet. 2. Remove the overhead outlet bezel from the rear headliner. 3. To install the outlet bezel, position the bezel in the outlet opening of the rear overhead duct and press inward firmly and evenly on both sides of the bezel until it snaps into place. Rear Side Panel Outlet Bezels Rear side panel outlet bezels are only used on models equipped with the optional rear heater-A/C unit. Rear Side Panel Outlet Bezels 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry between the edge of the outlet bezel and the rear side panel lower trim panel to release the snap clips that secure the bezel to the horizontal duct. 2. Remove the outlet bezel from the rear side panel lower trim panel. 3. To install the outlet bezel, position the bezel to the holes on the horizontal duct and press inward firmly and evenly on both sides of the bezel until the retaining clips snap into place. Vertical Duct The vertical duct is only used on models equipped with the optional rear heater-A/C unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Page 5638 Rear Heater-A/C Unit Ducts Remove/Install 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry out the plug that covers the vertical duct mounting screw. 2. Loosen but do not remove the screw that secures the vertical duct to the rear side panel strainer. Only loosen the screw far enough to disengage the vertical duct from the side panel. Gently pull the vertical duct away from the rear side panel while loosening the screw so that it can be determined when the screw is disengaged from the side panel. 3. Grasp the top of the vertical duct firmly with one hand and press upward on the inboard side of the duct opening in the headliner with the other hand. Pull the top of the duct downward and inboard until it unsnaps from the headliner duct opening. 4. Lift the vertical duct off of the rear heater-A/C unit duct outlet. 5. Reverse the removal procedures to install. Tighten the mounting screw to 2.2 N.m (20 in. lbs.). Horizontal Duct The horizontal duct is only used on models equipped with the optional rear heater-A/C unit. 1. Remove the outlet bezels from the rear side panel lower trim panel. See Ducts and Outlets - Rear Side Panel Outlet Bezels replacement procedures. 2. Remove the lower trim panels from the left rear side panel. 3. Remove the two retainers that secure the horizontal duct to the left rear side panel. 4. Lift the horizontal duct off of the rear heater-A/C unit duct outlet. 5. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation Blower Motor: Description and Operation SYSTEM OPERATION Front The front blower motor and blower wheel are located in the blower housing in the engine compartment. The blower housing is integral to the recirculation housing, which is secured to the dash panel and the right cowl side inner panel below the heater-A/C housing. The blower motor controls the velocity of air flowing through the heater-A/C system by spinning a squirrel cage-type blower wheel within the housing at the selected speed. The blower motor and blower wheel can be accessed for service from the engine compartment. The front blower motor will only operate when the ignition switch is in the On position, and when the heater-only or heater-A/C mode control switch knob is in any position, except Off. The blower motor receives a fused battery feed through the blower motor relay whenever the ignition switch is in the On position. The blower motor battery feed circuit is protected by a fuse in the Power Distribution Center (PDC). The blower motor relay control circuit is protected by a fuse in the junction block. Blower speed is controlled by regulating the blower motor ground path through the heater-A/C mode control switch, the front blower motor switch, the blower motor resistor, and the high speed blower motor relay. When the blower motor switch is placed in the highest speed position it energizes the high speed blower motor relay, which then provides a direct ground feed to the blower motor and bypasses the remainder of the blower motor control circuit. The blower motor and blower motor wheel cannot be repaired and, if faulty or damaged, they must be replaced. The blower motor and blower wheel are each serviced separately. Rear The rear blower motor and blower wheel are located in the optional rear heater-A/C unit housing in the passenger compartment. The rear heater-A/C unit is secured to the floor panel between the fuel filler inlet housing and the left rear wheel house against the left side panel. The blower motor controls the velocity of air flowing through the rear heater-A/C system by spinning a squirrel cage-type blower wheel within the housing at the selected speed. The blower motor and blower wheel can be accessed for service from the passenger compartment. The rear blower motor will only operate when the ignition switch is in the On position. The blower motor receives a fused battery feed through the blower motor relay whenever the ignition switch is in the On position. The blower motor battery feed circuit is protected by a fuse in the Power Distribution Center (PDC). The blower motor relay control circuit is protected by a fuse in the junction block. Blower speed is controlled by regulating the blower motor ground path through the blower motor switch, the blower motor resistor, and the high speed blower motor relay. When the rear blower motor switch is placed in the highest speed position it energizes the high speed blower motor relay, which then provides a direct ground feed to the blower motor and bypasses the remainder of the blower motor control circuit. The rear blower motor and blower motor wheel cannot be repaired and, if faulty or damaged, they must be replaced. The blower motor and blower wheel are each serviced separately. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Page 5642 Blower Motor: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR BAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Possible causes of an inoperative front or rear blower motor include: - Faulty fuse of Faulty blower motor circuit wiring or wire harness connectors Faulty blower motor resistor - Faulty blower motor relay - Faulty blower motor switch - Faulty heater-A/C mode control switch (front only) - Faulty high speed blower motor relay - Faulty blower motor. Possible causes of the front or rear blower motor not operating in all speeds include: - Faulty fuse - Faulty blower motor switch - Faulty blower motor resistor - Faulty blower motor relay - Faulty blower motor circuit wiring or wire harness connectors - Faulty high speed blower motor relay. Vibration Possible causes of front or rear blower motor vibration include: Improper blower motor mounting - Improper blower wheel mounting - Blower wheel out of balance or deformed - Blower motor faulty. Noise To verify that the blower is the source of the noise, unplug the blower motor wire harness connector and operate the heater-A/C system. If the noise goes away, possible causes include: Foreign material in the front or rear heater-A/C housing - Improper blower motor mounting - Improper blower wheel mounting - Blower motor faulty. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Page 5643 Blower Motor: Service and Repair Front REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the upper half of the radiator fan shroud. Front Blower Motor Remove/Install 3. Unplug the wire harness connector from the blower motor. 4. Remove the blower motor cooling tube from the nipple on the blower housing cover below the blower motor. 5. Remove the three screws that secure the blower motor mounting plate to the blower housing cover. 6. Remove the blower motor assembly from the blower housing. 7. If the vehicle is equipped with air conditioning, move the suction and discharge lines as required to remove the blower motor assembly from the engine compartment. 8. Remove the retainer clip from the hub of the blower wheel. 9. Remove the wheel from the blower motor shaft. INSTALLATION 1. Press the hub of the blower wheel onto the blower motor shaft. Be sure the flat on the blower motor shaft is indexed to the flat on the inside of the hub. 2. Install the retainer clip over the blower wheel hub. The ears of the retainer clip must be indexed over the flats on the blower motor shaft and blower wheel hub. 3. Apply a small bead of RTV rubber sealant to the blower motor side of the rubber seal and isolator unit. This will help to secure the seal to the blower mounting plate during installation. 4. Position the rubber seal and isolator unit to the blower motor mounting plate. 5. Position the blower motor and seal to the three mounting bosses on the blower housing cover and press the isolators over the mounting bosses. 6. Secure the blower motor mounting plate to the blower housing cover with the three mounting screws. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 7. Reinstall the blower motor cooling tube to the nipple on the blower housing cover. Blower Motor Wheel Remove/Install 8. Plug in the blower motor wire harness connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Page 5644 9. Reinstall the upper radiator fan shroud. 10. Connect the battery negative cable. REAR The rear blower motor is used only on models with the optional rear heater-A/C unit. The blower motor can be removed without removing the rear heater-A/C unit from the vehicle. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the rear heater-A/C unit. See Rear Heater-A/C Cover Replacement for the procedures. 3. Remove the vertical duct from the rear heater-A/C unit. See Ducts and Outlets - Vertical Duct. 4. Remove the horizontal duct from the rear heater-A/C unit. See Ducts and Outlets - Horizontal Duct. 5. Remove the upper housing from the rear heater-A/C unit. See Rear Heater-A/C Unit - Disassembly. Rear Blower Motor Remove/Install 6. Remove the three screws that secure the blower motor mounting plate to the rear heater-A/C unit upper housing. 7. Remove the blower motor assembly from the rear heater-A/C unit upper housing. 8. Remove the retainer clip from the hub of the blower wheel. 9. Remove the wheel from the blower motor shaft. INSTALLATION 1. Press the hub of the blower wheel onto the blower motor shaft. Be sure the flat on the blower motor shaft is indexed to the flat on the inside of the hub. 2. Install the retainer clip over the blower wheel hub. The ears of the retainer clip must be indexed over the flats on the blower motor shaft and blower wheel hub. 3. Position the rubber seal and isolator unit to the blower motor mounting plate. 4. Position the blower motor and seal to the three mounting bosses on the rear heater-A/C unit upper housing and press the isolators over the mounting bosses. 5. Secure the blower motor mounting plate to the rear heater-A/C unit upper housing with the three mounting screws. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 6. Reinstall the upper housing onto the rear heater-A/C unit. See Rear Heater-A/C Unit - Assembly Replacement for the procedures. 7. Reinstall the horizontal duct to the rear heater-A/C unit. See Ducts and Outlets - Horizontal Duct. 8. Reinstall the vertical duct to the rear heater-A/C unit. See Ducts and Outlets - Vertical Duct. 9. Reinstall the cover to the rear heater-A/C unit. See Rear Heater-A/C Cover Replacement for the procedures. 10. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description and Operation > Blower Motor Relay Blower Motor Relay: Description and Operation Blower Motor Relay SYSTEM OPERATION Front The front blower motor relay is a International Standards Organization (ISO)-type relay. The relay is a electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) directly to the blower motor. The relay is energized when the relay coil is provided a voltage signal by the ignition switch. This arrangement reduces the amount of battery current that must flow through the ignition switch. The blower motor relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motor receives no battery current. See Blower Motor Relay in the Diagnosis and Testing for more information. The front blower motor relay is located in the PDC in the engine compartment. Refer to the PDC label for blower motor relay identification and location. The blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Rear The blower motor relay for the optional rear heater-A/C unit is a International Standards Organization (ISO)-type relay. The relay is a electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) directly to the blower motor. The relay is energized when the relay coil is provided a voltage signal by the ignition switch. This arrangement reduces the amount of battery current that must flow through the ignition switch. The blower motor relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motor receives no battery current. See Blower Motor Relay in the Diagnosis and Testing for more information. The rear blower motor relay is located in a connector that is secured to the back of the rear heater-A/C unit housing in the passenger compartment. See Blower Motor Relay - Rear in the Removal and Installation for rear blower motor relay identification and location. The blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description and Operation > Blower Motor Relay > Page 5650 Blower Motor Relay: Description and Operation High Speed Blower Motor Relay SYSTEM OPERATION Front The front blower motor electrical circuit uses a high speed blower motor relay. The high speed blower motor relay is a International Standards Organization (1S0)-type relay The relay is a electromechanical device that switches the blower motor to ground, bypassing the remainder of the blower motor feed circuit. The high speed blower motor relay is energized when the relay coil is provided a ground signal by the blower motor switch, and a battery feed from the ignition switch. When the relay is de-energized, the front blower motor ground feed is routed through the front blower motor switch and the blower motor resistor. See High Speed Blower Motor Relay in the Diagnosis and Testing for more information. The front high speed blower motor relay is located in the engine compartment, on a bracket that is secured under one of the screws for the top cover on the inboard side of the heater-A/C housing. The high speed blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Rear The optional rear heater-A/C unit blower motor electrical circuit uses a high speed blower motor relay The high speed blower motor relay is a International Standards Organization (IS0)-type relay The relay is a electromechanical device that switches the blower motor to ground, bypassing the remainder of the blower motor feed circuit. The high speed blower motor relay is energized when the relay coil is provided a ground signal by the blower motor switch, and a battery feed from the ignition switch. When the relay is de-energized, the rear blower motor ground feed is routed through the rear blower motor switch and the blower motor resistor. See High Speed Blower Motor Relay in the Diagnosis and Testing for more information. The rear high speed blower motor relay is located in a connector that is secured to the back of the rear heater-A/C unit housing in the passenger compartment. See High Speed Blower Motor Relay Rear in the Removal and Installation for rear high speed blower motor relay identification and location. The rear high speed blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay Blower Motor Relay: Testing and Inspection Blower Motor Relay Blower Motor Relay Relay Test The blower motor relays used for the front heater-only or heater-A/C systems and for the optional rear heater-A/C unit can be tested in the same manner. The front blower motor relay is located in the Power Distribution Center (PDC). The rear blower motor relay is located in a connector that is attached to the back of the rear heater-A/C unit. See Blower Motor Relay in the Removal and Installation for the procedures to remove the relay, to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to fused battery feed directly from a fuse in the Power Distribution Center (PDC), and should be hot at all times. Check for battery voltage at the PDC cavity for relay terminal 30. If OK, go to Step 3. If not OK repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 4. 3. The relay normally open terminal cavity (87) is connected to the blower motor. When the relay is energized, terminal 87 is connected to terminal 30 and provides full battery current to the blower motor feed circuit. There should be continuity between the PDC cavity for terminal 87 and the blower motor relay output circuit cavity of the blower motor wire harness connector at all times. If OK, go to Step 5. If not OK, repair the open circuit to the blower motor as required. 4. The coil battery terminal cavity (86) is connected to the ignition switch. When the ignition switch is placed in the On position, fused ignition switch output is directed from a fuse in the junction block to the relay electromagnetic coil to energize the relay. There should be battery voltage at the PDC cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 6. If not OK, repair the open circuit to the junction block fuse as required. 5. The coil ground terminal cavity (85) is connected to ground. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the PDC cavity for relay terminal 85 and a good ground at all times. If not OK, repair the open circuit as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 5653 Blower Motor Relay: Testing and Inspection High Speed Blower Motor Relay Blower Motor Relay Relay Test The high speed blower motor relays used for the front heater-only or heater-A/C systems and for the optional rear heater-A/C unit can be tested in the same manner. The front high speed blower motor relay is located in the engine compartment on a bracket mounted to the inboard side of the heater-A/C housing. The rear high speed blower motor relay is located in a connector that is attached to the back of the rear heater-A/C unit. See Blower Motor Relay in the Removal and Installation procedures to remove the relay, to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the ground side of the front or rear blower motor. There should be continuity between the ground circuit cavity of the front or rear blower motor wire harness connector and the wire harness connector cavity for relay terminal 30 at all times. If OK, go to Step 3. If not OK, repair the open circuit to the front or rear blower motor as required. 2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 4. 3. The relay normally open terminal cavity (87) is connected to ground. When the relay is energized, terminal 87 is connected to terminal 30 and provides a direct path to ground for the front or rear blower motor. There should be continuity between the wire harness connector cavity for relay terminal 87 and ground at all times. If OK, go to Step 5. If not OK, repair the open circuit to ground as required. 4. The coil battery terminal cavity (86) is connected to the ignition switch. When the ignition switch is placed in the On position, fused ignition switch output is directed from a fuse in the junction block to the relay electromagnetic coil to energize the relay. There should be battery voltage at the wire harness connector cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 6. If not OK, repair the open circuit to the junction block fuse as required. 5. The coil ground terminal cavity (85) is connected to the high speed output circuit terminal of the front or rear blower motor switch. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the wire harness connector cavity for relay terminal 85 and the high speed output circuit terminal of the front or rear blower motor switch at all times. If not OK, repair the open circuit to the front or rear blower motor switch as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Page 5654 Blower Motor Relay: Service and Repair Front 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for blower motor relay identification and location. 4. Unplug the blower motor relay from the PDC. 5. Install the blower motor relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Rear The rear blower motor relay is used only on models with the optional rear heater-A/C unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the rear heater-A/C unit. Rear Blower Motor Relay Remove/Install 3. Unplug the blower motor relay from the inboard relay wire harness connector, which is secured to the rear of the rear heater-A/C unit. 4. Install the blower motor relay by aligning the relay terminals with the cavities in the wire harness connector and pushing the relay firmly into place. 5. Reinstall the cover for the rear heater-A/C unit. 6. Connect the battery negative cable. 7. Test the relay operation. High Speed Blower Motor Relay Front 1. Disconnect and isolate the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Page 5655 Front High Speed Blower Motor Relay Remove/Install 2. The high speed blower motor relay is retained by a snap fit to the blade of the mounting bracket on the inboard side of the heater-A/C housing. Unsnap the relay from the mounting bracket by sliding it downwards. 3. Unplug the wire harness connector from the high speed blower motor relay. 4. Install the high speed blower motor relay by aligning the relay terminals with the cavities in the relay wire harness connector and pushing the relay firmly into place. 5. Slide the molded receptacle on the high speed blower motor relay case back onto the blade of the mounting bracket until it snaps into place. 6. Connect the battery negative cable. 7. Test the relay operation. Rear The rear high speed blower motor resistor is used only on models with the optional rear heater-A/C unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the rear heater-A/C unit. Rear High Speed Blower Motor Relay Remove/Install 3. Unplug the high speed blower motor relay from the outboard relay wire harness connector, which is secured to the rear of the rear heater-A/C unit. 4. Install the high speed blower motor relay by aligning the relay terminals with the cavities in the wire harness connector and pushing the relay firmly into place. 5. Reinstall the cover for the rear heater-A/C unit. 6. Connect the battery negative cable. 7. Test the relay operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation Blower Motor Resistor: Description and Operation SYSTEM OPERATION Front The front blower motor resistor is mounted to the inboard side of the heater-A/C housing in the engine compartment. It can be accessed for service from the engine compartment. It is secured to the housing with two screws and is connected to the headlamp and dash wire harness. See Blower Motor Resistor - Front in the Removal and Installation for more information. The blower motor resistor has multiple resistor wires, each of which will change the resistance in the blower motor ground path to change the blower motor speed. The blower motor switch directs the ground path through the correct resistor wire to obtain the selected blower motor speed. With the blower motor switch in the lowest speed position the ground path for the motor is applied through all of the resistor wires. Each higher speed selected with the blower motor switch applies the blower motor ground path through fewer of the resistor wires, increasing the blower motor speed. When the blower motor switch is in the highest speed position, the blower motor resistor is bypassed and the blower motor receives a direct path to ground through the high speed blower motor relay. The front blower motor resistor cannot be repaired and, if faulty or damaged, it must be replaced. Rear The optional rear heater-A/C unit has a blower motor resistor mounted to the inside of the unit lower housing in the passenger compartment. It can be accessed for service through the horizontal duct opening in the rear heater-A/C unit upper housing. It is secured to the inside of the lower housing by two mounting tabs and a snap feature that are molded into the lower housing, and it is connected to the rear heater-A/C unit wire harness. See Blower Motor Resistor - Rear in the Removal and Installation for more information. The blower motor resistor has multiple resistor wires, each of which will change the resistance in the blower motor ground path to change the blower motor speed. The blower motor switch directs the ground path through the correct resistor wire to obtain the selected blower motor speed. With the blower motor switch in the lowest speed position the ground path for the motor is applied through all of the resistor wires. Each higher speed selected with the blower motor switch applies the blower motor ground path through fewer of the resistor wires, increasing the blower motor speed. When the blower motor switch is in the highest speed position, the blower motor resistor is bypassed and the blower motor receives a direct path to ground through the high speed blower motor relay The rear blower motor resistor cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Page 5659 Blower Motor Resistor: Testing and Inspection The blower motor resistors used for the front heater-only or heater-A/C systems and for the optional rear heater-A/C unit can be tested in the same manner. The front blower motor resistor is located in the engine compartment on the inboard side of the heater-A/C housing. The rear blower motor resistor is located in lower housing of the rear heater-A/C unit in the passenger compartment. The front blower motor resistor can be tested without removing it from its mounting position. The rear blower motor resistor must be removed from its mounting position to be tested. See Blower Motor Resistor - Rear in the Removal and Installation procedures. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR-BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the blower motor resistor. 3. Check for continuity between each of the blower motor switch input terminals of the resistor and the resistor output terminal. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor switch and the blower motor resistor or blower motor as required. If not OK, replace the faulty blower motor resistor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Page 5660 Blower Motor Resistor: Service and Repair Front REMOVAL 1. Disconnect and isolate the battery negative cable. Front Blower Motor Resistor Remove/Install 2. Unplug the wire harness connector from the blower motor resistor, which is located on the inboard side of the heater-A/C housing. 3. Remove the two screws that secure the blower motor resistor to the heater-A/C housing. 4. Remove the front blower motor resistor from the heater-A/C housing. INSTALLATION 1. Position the front blower motor resistor to the mounting hole on the inboard side of the heater-A/C housing. 2. Secure the front blower motor resistor to the heater-A/C housing with two screws. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 3. Plug the wire harness connector into the front blower motor resistor. 4. Connect the battery negative cable. Rear The rear blower motor resistor is used only on models with the optional rear heater-A/C unit. REMOVAL 1. Before beginning this procedure, place the rear heater-A/C unit in the heat mode by turning the ignition switch to the On position and placing the temperature control knob on the heater-A/C control in the full hot position. 2. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. 3. Remove the cover from the rear heater-A/C unit. 4. Reach under the front of the rear heater-A/C unit to access and unplug the wire harness connector from the rear blower motor resistor. 5. Remove the horizontal duct from the rear heater-A/C unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Page 5661 Rear Blower Motor Resister Remove/Install 6. Reach through the horizontal duct outlet in the rear heater-A/C unit upper housing with a small hand or use large pliers to access the blower motor resistor. 7. Push firmly against the inboard side of the blower motor resistor shield toward the outboard side of the vehicle until the resistor unsnaps from the retainer in the lower housing. 8. Pull the blower motor resistor out of the rear heater-A/C housing through the horizontal duct outlet. INSTALLATION 1. Lower the blower motor resistor into the rear heater-A/C unit upper housing horizontal duct outlet. 2. Slide the outboard edge of the blower motor resistor mounting flange under the two tabs on the outboard edge of the resistor mounting hole in the lower housing. 3. Reach under the front of the rear heater-A/C unit to hold the blower motor resistor against the outboard side of the mounting hole with one hand. Then, use the other hand to reach through the horizontal duct outlet from above and press firmly downward on the inboard side of the resistor shield until the inboard side of the resistor mounting flange snaps under the retainer on the inboard side of the mounting hole in the lower housing. 4. Reach under the front of the rear heater-A/C unit to access and plug in the wire harness connector to the rear blower motor resistor. 5. Reinstall the horizontal duct to the rear heater- A/C unit. 6. Reinstall the cover over the rear heater-A/C unit. 7. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation SYSTEM OPERATION Front The front blower motor is controlled by a four position rotary-type blower motor switch, mounted in the heater-only or heater-A/C control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned off by selecting the Off position with the heater-A/C mode control switch knob. The blower motor switch directs the blower motor ground path from the mode control switch to the blower motor resistor, or directly to ground through the high speed blower motor relay, as required to achieve the selected blower motor speed. The front blower motor switch cannot be repaired and, if faulty or damaged, the entire heater-only or heater-A/C control unit must be replaced. The blower motor switch knob is serviced separately Rear The optional rear heater-A/C unit blower motor is controlled by a four position rotary-type blower motor switch, mounted in the accessory switch plate located to the right of the heater-A/C control on the instrument panel. The switch allows the selection of one of three blower motor speeds and an Off position. The rear blower motor switch directs the blower motor ground path to the blower motor resistor, or directly to ground through the high speed blower motor relay as required to achieve the selected blower motor speed. The rear blower motor switch cannot be repaired and, if faulty or damaged, it must be replaced. The rear blower motor switch knob is serviced separately The rear blower motor switch also has a replaceable incandescent-type illumination lamp bulb. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation > Page 5665 Blower Motor Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR-BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Front 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the heater-A/C control from the instrument panel. See Heater-A/C Control Replacement for the procedures. Check for continuity between the ground circuit (Z1V) cavity of the heater-A/C mode control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 2. With the heater-A/C control wire harness connector unplugged, place the heater-A/C mode control switch knob in any position except the Off position. Check for continuity between the two ground circuit terminals in the mode switch receptacle of the heater-A/C control. There should be continuity. If OK, go to Step 4. If not OK, replace the faulty heater-A/C control unit. 3. Check for continuity between the ground circuit (C 72) cavities of the heater-A/C mode control wire harness connector and the heater-A/C blower speed switch wire harness connector. There should be continuity. If OK, go to Step 5. If not OK, repair the open circuit as required. 4. Check for continuity between the ground circuit (C 72) terminal and each of the blower motor driver circuit terminals in the blower speed switch receptacle of the heater-A/C control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the heater-A/C control blower speed switch wire harness connector and the front blower motor resistor or the front high speed blower motor relay as required. If not OK, replace the faulty heater-A/C control unit. Rear 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the accessory switch plate from the instrument panel. Refer to Accessory Switch Plate in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel for the procedures. Check for continuity between the ground circuit cavity of the rear blower motor switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 2. With the rear blower motor switch wire harness connector unplugged, place the rear blower motor switch knob in any position except the Off position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the rear blower motor switch as you move the blower motor switch knob to each of the three speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the rear blower driver circuits between the rear blower motor switch wire harness connector and the rear blower motor resistor or the rear high speed blower motor relay as required. If not OK, replace the faulty rear blower motor switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation > Page 5666 Blower Motor Switch: Service and Repair The rear blower motor switch is used only on models with the optional rear heater-A/C unit. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the accessory switch plate from the instrument panel. Refer to Accessory Switch Plate in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel procedures. Rear Blower Motor Remove/Install 3. Rotate the illumination lamp socket counterclockwise to disengage it from the back of the switch housing. 4. Pull the knob off of the blower motor switch stem from the front of the accessory switch plate. 5. With a small thin-bladed screwdriver, gently pry the sides of the accessory switch plate to release the two snap clips on each side of the rear blower motor switch housing. 6. Remove the rear blower motor switch from the back of the accessory switch plate. INSTALLATION 1. Position the rear blower motor switch on the back of the accessory switch plate. 2. Firmly and evenly press the rear blower motor switch into the back of the accessory switch plate until it snaps into place. Be certain that all of the switch snap clip retainers are fully engaged. 3. Reinstall the knob onto the rear blower motor switch stem from the front of the accessory switch plate. Be certain to index the flat on the switch stem with the flat in the hub of the knob. 4. Reinstall the illumination lamp socket to the back of the rear blower motor switch housing. 5. Reinstall the accessory switch plate in the instrument panel. Refer to Accessory Switch Plate in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel procedures. 6. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Clutch Air Gap ..................................................................................................................................... .......................... 0.35 - 0.65 mm (0.013 to 0.025 in.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5671 8w-80-4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5672 Compressor Clutch: Description and Operation SYSTEM OPERATION Compressor Clutch - Typical The compressor clutch assembly consists of a stationary electromagnetic coil, a hub bearing and pulley assembly, and a clutch plate. The electromagnetic coil unit and the hub bearing and pulley assembly are each retained on the nose of the compressor front housing with snap rings. The clutch plate is mounted on the compressor shaft and secured with a nut. These components provide the means to engage and disengage the compressor from the engine serpentine accessory drive belt. When the clutch coil is energized, it magnetically draws the clutch into contact with the pulley and drives the compressor shaft. When the coil is not energized, the pulley freewheels on the clutch hub bearing, which is part of the pulley. The compressor clutch and coil are the only serviced parts on the compressor. The compressor clutch is controlled by several components: the heater-A/C mode control switch, the low pressure cut-off switch, the high pressure cut-off switch, the fin sensing cycling clutch switch, the thermal limiter switch, the compressor clutch relay, and the Powertrain Control Module (PCM). The PCM may delay compressor clutch engagement for up to thirty seconds. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5673 Compressor Clutch: Service and Repair The refrigerant system can remain fully-charged during compressor clutch, pulley, or coil replacement. The compressor clutch can be serviced in the vehicle. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the serpentine drive belt. 3. Unplug the compressor clutch coil wire harness connector. Clutch Nut Remove 4. install two 6 millimeter screws into the threaded holes in the front of the clutch plate. Use two box-end wrenches over the screws to hold the clutch plate stationary and remove the hex nut. CAUTION: Do not pry between the clutch plate and the clutch pulley to remove the plate. Failure to observe this caution may result in damage to the compressor clutch assembly. 5. Remove the clutch plate and the clutch shims. If necessary, tap the clutch plate lightly with a plastic hammer to loosen it. 6. Remove the compressor clutch pulley retaining snap ring with snap ring pliers. 7. Remove the clutch pulley assembly from the compressor. If necessary, tap the clutch pulley lightly with a plastic hammer to loosen it. 8. Remove the screw and retainer from the clutch coil lead wire harness on the compressor front housing. 9. Unplug the compressor clutch wire harness connectors from the thermal limiter switch. 10. Note the alignment of the clutch field coil assembly on the compressor before removing it for correct reinstallation. Clutch/Pulley/Coil Remove/Install 11. Remove the snap ring that secures the clutch field coil assembly to the compressor front housing. 12. Remove the clutch field coil assembly from the compressor front housing. Inspection Examine the friction surfaces of the clutch pulley and the front plate for wear. The pulley and front plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft and nose area of the compressor for oil. If excessive oil is present, the shaft seal is leaking and the compressor must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5674 Check the clutch pulley bearing for roughness or excessive leakage of grease. Replace the bearing, if required. INSTALLATION 1. Position the back of the clutch field coil against the compressor front housing. Be certain that the locating pin on the back of the coil lines up with the indentation on the compressor front housing. This ensures the proper orientation of the coil and the wire harness. 2. Install the clutch field coil snap ring (bevel side outward) with snap ring pliers. Be certain that the snap ring is properly seated into the groove. CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in a clutch failure and severe damage to the front housing of the compressor. 3. Install the clutch coil lead wire harness retaining clip on the compressor front housing and tighten the retaining screw. 4. Plug in the compressor clutch wire harness connectors to the thermal limiter switch. 5. Position the clutch pulley assembly onto the compressor. CAUTION: Do not mar or contaminate the clutch pulley friction surface. 6. Install the clutch pulley assembly snap ring (bevel side outward) with snap ring pliers. Be certain that the snap ring is properly seated in the groove. 7. Place a trial stack of shims, 2.54 millimeters (0.10 inch) thick, on the compressor shaft. Aligning Clutch Plate Splines 8. Note the machined mating splines on the compressor shaft and in the clutch plate hub. 9. Align the mating splines and install the clutch plate on the compressor shaft. 10. Install the external front rotor snap ring with snap ring pliers. The bevel side of the snap ring must be facing outward. Press the snap ring to make sure it is properly seated in the groove. Check Clutch Air Gap 11. With the front clutch plate assembly tight against the shims, measure the air gap between the clutch plate and the pulley face with a feeler gauge. The air gap should be from 0.35 to 0.65 millimeter (0.013 to 0.025 inch). If the proper air gap is not obtained, add or subtract shims until the desired air gap is obtained. 12. Install the compressor shaft nut. Tighten the nut to 14.4 N.m (10.5 ft. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5675 13. The shims may compress after tightening the compressor shaft nut. Check the air gap in four or more places to verify that the air gap is still correct. Spin the pulley for a final check. 14. Reverse the remaining removal procedures to complete the installation. Clutch Break-In After a new compressor clutch has been installed, cycle the compressor clutch approximately twenty times (five seconds on, then five seconds off). During this procedure, set the heater-A/C control to the recirculation mode (Max-A/C), the blower motor switch in the highest speed position, and the engine speed at 1500 to 2000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection Compressor Clutch Coil: Testing and Inspection The battery must be fully-charged before performing the following tests. Refer to Starting and Charging/Battery for more information. 1. Connect an ammeter (0 to 10 ampere scale) in series with the clutch coil terminal. Use a voltmeter (0 to 20 volt scale) with clip-type leads for measuring the voltage across the battery and the compressor clutch coil. 2. With the heater-A/C mode control switch in any A/C mode, and the blower motor switch in the lowest speed position, start the engine and run it at normal idle. 3. The compressor clutch coil voltage should read within two volts of the battery voltage. If there is voltage at the clutch coil, but the reading is not within Two Volts of the battery voltage, test the clutch coil feed circuit for excessive voltage drop and repair as required. If there is no voltage reading at the clutch coil, use a DRB scan tool and the proper Diagnostic Procedures for testing of the compressor clutch circuit. The following components must be checked and repaired as required before you can complete testing of the clutch coil: Fuses in the junction block and the Power Distribution Center - Heater-A/C mode control switch - Compressor clutch relay - Fin sensing cycling clutch switch - High pressure cut-off switch - Low pressure cut-off switch - Thermal limiter switch - Powertrain Control Module. 4. The compressor clutch coil is acceptable if the current draw measured at the clutch coil is 2.0 to 3.9 amperes with the electrical system voltage at 11.5 to 12.5 volts. This should only be checked with the work area temperature at 210 C (700 F). If system voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until the system voltage drops below 12.5 volts. a. If the clutch coil current reading is four amperes or more, the coil is shorted and should be replaced. b. If the clutch coil current reading is zero, the coil is open and should be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Component Locations Compressor Clutch Relay: Component Locations 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 5683 A/C Compressor Clutch Relay Connector, PDC. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 5684 A/C Compressor Clutch Relay Connector, PDC. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5685 Compressor Clutch Relay: Description and Operation SYSTEM OPERATION The compressor clutch relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The compressor clutch relay is a electromechanical device that switches battery current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay. The PCM responds to inputs from the heater-A/C mode control switch, the low pressure cut-off switch, the high pressure cut-off switch, and the fin sensing cycling clutch switch. See Compressor Clutch Relay in the Diagnosis and Testing for more information. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5686 Compressor Clutch Relay: Testing and Inspection Relay Test Compressor Clutch Relay The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 3. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 4. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 5. If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 6. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5687 Compressor Clutch Relay: Service and Repair Power Distribution Center REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug the compressor clutch relay from the PDC. 5. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation Condenser HVAC: Description and Operation SYSTEM OPERATION The condenser is located in the air flow in front of the engine cooling radiator. The condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the compressor to give up its heat to the air passing over the condenser fins. When the refrigerant gas gives up its heat, it condenses. When the refrigerant leaves the condenser, it has become a high-pressure liquid refrigerant. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the air conditioning system. Therefore, it is important that there are no objects placed in front of the radiator grille openings in the front of the vehicle or foreign material on the condenser fins that might obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or condenser service. The condenser cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 5691 Condenser HVAC: Service and Repair WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. CAUTION: Before removing the condenser, note the location of each of the radiator and condenser air seals. These seals are used to direct air through the condenser and radiator. The air seals must be reinstalled in their proper locations in order for the air conditioning and engine cooling systems to perform as designed. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the radiator grille from the vehicle. 4. Disconnect the discharge line from the condenser inlet. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Disconnect the liquid line from the condenser outlet. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Remove the upper radiator support from the vehicle. Condenser Remove/Install 7. Remove the nuts that secure the condenser to the front of the right and left radiator core supports. INSTALLATION 1. Carefully position the condenser mounting brackets over the screws on the right and left radiator core supports. 2. Reinstall the nuts that secure the condenser mounting brackets to the radiator core supports. Tighten the mounting nuts to 11.8 N.m (105 in. lbs.). 3. Reinstall the upper radiator support in the vehicle. 4. Remove the plugs or tape from the refrigerant line fittings on the liquid line and the condenser outlet. Connect the liquid line to the condenser outlet. See Liquid Line Replacement for the procedures. 5. Remove the plugs or tape from the refrigerant line fittings on the discharge line and the condenser inlet. Connect the discharge line to the condenser inlet. See Suction and Discharge Line Replacement for the procedures. 6. Check that all of the condenser and radiator air seals are in their proper locations. 7. Reinstall the radiator grille in the vehicle. 8. Connect the battery negative cable. 9. Evacuate the refrigerant system. 10. Charge the refrigerant system. NOTE: If the condenser is replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams 8w-80-4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 5695 Control Assembly: Testing and Inspection Heater System Diagnosis Mode Control Satisfactory heater and air conditioner performance depends upon proper operation and adjustment of all operating controls and refrigeration system components. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 5696 Operation must be tested as described in the following sequence: 1. Inspect and adjust the serpentine drive belt. 2. Start the engine and set the engine speed to 1,300 rpm. 3. Move the temperature control knob to the full counterclockwise (Cool) position and place the mode control knob in the Bi-Level position. The outside (recirculation) air door should be open to outside air. If not OK, see Vacuum System. 4. With the temperature control knob in the full counterclockwise (Cool) position, the air being discharged from the outlets should be near ambient temperature. As the temperature control knob is rotated clockwise beyond the third detent, a gradual warming of the air being discharged should be noticed. If OK, go to Step 7. If not OK, go to Step 6. 5. Roll down the glove box from the instrument panel. Refer to Glove Box - Roll Down in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel for the procedures. Look through the instrument panel glove box opening to locate the blend-air door motor on the top of the distribution duct. While rotating the temperature control knob through its travel, check that the blend-air door motor lever is moving and that the blend-air door link is connected to the lever. If OK, see Heater Performance. If not OK, see Blend-Air Door Control. 6. Open the vehicle windows. Test the blower motor operation in all speeds. If not OK, see the tests for the individual blower motor components. Leave the blower motor switch in the highest speed position. 7. On vehicles with air conditioning, the compressor should be running and the air conditioning system in operation. If not OK, see A/C Performance in the Diagnosis and Testing. 8. Check the heater-only or heater-A/C mode control switch operation. The systems should respond as shown in the Mode Control chart. Reduce the engine speed to normal idle. The vacuum will be high at low idle and the actuators should respond quickly. If not OK, see Vacuum System - Heater-A/C Controls. 9. If the vacuum tests, and the electrical component and circuit tests reveal no problems, disassemble the heater-A/C housing, the recirculation housing and the distribution duct to inspect for mechanical misalignment or binding of the mode doors. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 5697 Control Assembly: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the engine cover from the passenger compartment. 3. Reach between the upper dash panel engine housing extension and the bottom of the instrument panel to access and unplug the vacuum harness connector, which is located near the left defroster outlet of the distribution duct. 4. Remove the cluster bezel from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Cluster Bezel Replacement. Heater-A/C Control Remove/Install 5. Remove the three screws that secure the heater-A/C control to the instrument panel. 6. Pull the heater-A/C control assembly away from the instrument panel far enough to access the connections on the back of the control. Heater-A/C Control Connections 7. Unplug the wire harness connectors from the back of the heater-A/C control. 8. Remove the heater-A/C control from the instrument panel. INSTALLATION 1. Plug in the wire harness connectors to the back of the heater-A/C control. 2. Position the heater-A/C control in the instrument panel and secure it with three screws. Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Reinstall the cluster bezel to the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Cluster Bezel Replacement. 4. Reach between the upper dash panel engine housing extension and the bottom of the instrument panel to access and plug in the two halves of the vacuum harness connector. 5. Reinstall the engine cover in the passenger compartment. 6. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5706 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5707 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5708 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5709 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5710 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5711 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5712 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5713 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5714 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5715 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5716 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5717 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5723 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5724 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5725 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5726 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5727 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5728 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5729 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5730 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5731 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5732 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5733 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5734 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Combination Coil Evaporator Core: Description and Operation Combination Coil SYSTEM OPERATION Models equipped with the optional rear heater-A/C unit have a combination coil located within the rear unit housing. It is called a combination coil because it combines the functions of a heater core and an evaporator coil into a single heat exchanger unit. The combination coil features six rows of tube and fin construction. The two rows located toward the outboard side of the vehicle serve as the heater core and have engine coolant circulated through them whenever the rear water valve is open. The four rows toward the inboard side of the vehicle serve as the evaporator and have refrigerant circulated through them whenever the air conditioning compressor is operating. The amount of refrigerant flowing through the combination coil is controlled by a dedicated rear thermal expansion valve. The combination coil can be accessed for service by removing the rear heater-A/C unit upper housing. The combination coil cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Combination Coil > Page 5737 Evaporator Core: Description and Operation Evaporator Coil SYSTEM OPERATION Front The evaporator coil is located in the heater-A/C housing, on the right side of the engine compartment. The evaporator coil is positioned in the heater-A/C housing so that all air that enters the housing must pass over the fins of the evaporator before it is distributed through the system ducts and outlets. However, air passing over the evaporator coil fins will only be conditioned when the compressor is engaged and circulating refrigerant through the evaporator coil tubes. Refrigerant enters the evaporator from the expansion valve as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a hightemperature, low-pressure gas before it leaves the evaporator. The evaporator coil cannot be repaired and, if faulty or damaged, it must be replaced. Rear Models equipped with the optional rear heater-A/C unit have a combination coil located within the rear unit housing. The combination coil functions as both the rear heater core and the rear evaporator coil. See Combination Coil in the Description and Operation for more information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Combination Coil Removal and Installation Evaporator Core: Service and Repair Combination Coil Removal and Installation The combination coil is used only on models with the optional rear heater-A/C unit. The combination coil can be removed without removing the rear heater-A/C unit from the vehicle. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the expansion valve from the combination coil. 3. Drain the engine cooling system. Refer to: "Engine, Cooling and Exhaust : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 4. Disconnect the rear heater-A/C unit heater hoses from the combination coil heater tubes. Install plugs in, or tape over the opened combination coil heater tubes and hoses. 5. Remove the vertical duct from the rear heater-A/C unit. 6. Remove the horizontal duct from the rear heater-A/C unit. 7. Remove the upper housing from the rear heater-A/C unit. Evaporator Coil Remove/Install 8. Lift the combination coil out of the rear heater-A/C unit lower housing. INSTALLATION 1. Insert the combination coil into the bottom of the rear heater-A/C unit lower housing. 2. Reinstall the upper housing onto the rear heater-A/C unit. 3. Reinstall the horizontal duct to the rear heater- A/C unit. 4. Reinstall the vertical duct to the rear heater-A/C unit. 5. Unplug or remove the tape from the rear heater-A/C unit combination coil heater tubes and hoses. Connect the heater hoses to the combination coil heater tubes and fill the engine cooling system. 6. Reinstall the expansion valve to the combination coil. NOTE: If the combination coil is replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Combination Coil Removal and Installation > Page 5740 Evaporator Core: Service and Repair Evaporator Core Replacement WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. Front REMOVAL 1. Remove the heater-A/C housing from the engine compartment. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair 2. Remove the top cover from the heater-A/C housing. 3. Remove the expansion valve from the evaporator coil. 4. Remove the fin sensing cycling clutch switch probe from the evaporator coil. Evaporative Coil Remove/Install 5. Lift the evaporator coil out of the heater-A/C housing. INSTALLATION 1. Insert the evaporator coil into the bottom of the heater-A/C housing. 2. Reinstall the expansion valve to the evaporator coil. 3. Reinstall the fin sensing cycling clutch switch probe to the evaporator coil. 4. Reinstall the top cover onto the heater-A/C housing. 5. Reinstall the heater-A/C housing in the engine compartment. NOTE: If the front evaporator coil is replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Rear The evaporator coil for the optional rear heater-A/C unit is integral with the rear heating system heater core. This unit is referred to as the combination coil. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation Expansion Valve: Description and Operation SYSTEM OPERATION Front The front "H" valve-type thermal expansion valve (TXV) is located at the front of the heater-A/C housing between the liquid and suction lines and the evaporator coil. High-pressure, high temperature liquid refrigerant from the liquid line passes through the expansion valve orifice, converting it into a low- pressure, low-temperature mixture of liquid and gas before it enters the evaporator coil. A temperature sensor in the expansion valve control head monitors the temperature of the refrigerant leaving the evaporator coil through the suction line and adjusts the orifice size at the liquid line to let the proper amount of refrigerant into the evaporator coil to meet the vehicle cooling requirements. Controlling the refrigerant flow through the evaporator ensures that none of the refrigerant leaving the evaporator is still in a liquid state, which could damage the compressor. The expansion valve is a factory calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the expansion valve must be replaced. Rear Models equipped with the optional rear heater-A/C unit have a second "H" valve-type thermal expansion valve (TXV) installed between the rear unit liquid and suction lines, and the combination coil. High pressure, high temperature liquid refrigerant from the liquid line passes through the expansion valve orifice, converting it into a low-pressure, low-temperature mixture of liquid and gas before it enters the combination coil. A temperature sensor in the expansion valve control head monitors the temperature of the refrigerant leaving the combination coil through the suction line, and adjusts the orifice size at the liquid line to let the proper amount of refrigerant into the combination coil to meet the vehicle cooling requirements. Controlling the refrigerant flow through the combination coil ensures that none of the refrigerant leaving the combination coil is still in a liquid state, which could damage the compressor The rear expansion valve is a factory calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the expansion valve must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > Page 5744 Expansion Valve: Testing and Inspection These tests must be made at an ambient temperature of 21 to 290 C (70 to 850 F). Front (ONLY) 1. Attach a manifold gauge set. Close the vehicle doors and windows, start the engine, and hold the engine speed at 1,000 rpm. Set the heater-A/C mode control switch knob in the recirculation mode (Max A/C) position, the temperature control knob in the full hot position, and the blower motor switch in the highest speed position. Disconnect and plug the vacuum harness connector at the water valve in the engine compartment. Unplug the fin sensing cycling clutch switch wire harness connector. 2. Operate the air conditioning system for at least five minutes to stabilize the system, and to provide sufficient reheat to load the evaporator. The discharge pressure (high side) at the service port should reach 966 to 1656 kPa (140 to 240 psi). If this discharge pressure cannot be obtained, check the refrigerant system charge. See Refrigerant System Charge in the Service Procedures. WARNING: EXTREME CARE MUST BE USED WHEN HANDLING LIQUID CARBON DIOXIDE (CO2), AS SKIN INJURY CAN OCCUR. PROTECTIVE GLOVES SHOULD BE WORN. 3. Apply liquid carbon dioxide (CO2) to the expansion valve control head (completely cover the head) for a minimum of thirty seconds. Observe the manifold gauge set. The suction pressure (low side) must drop to below 50 kPa (7.25 psi). If this reading is not obtained, the expansion valve is faulty and must be replaced. 4. Remove the liquid carbon dioxide (CO2) from the control head. Observe the manifold gauge set. The suction pressure (low side) must increase to a minimum of 262 kPa (38 psi), and then stabilize to a pressure of 172 to 240 kPa (25 to 35 psi). If these readings are not obtained, the expansion valve is faulty and must be replaced. 5. Set the engine idle speed at 1,000 rpm and the blower motor switch in the highest speed position. The suction pressure (low side) should be 138 to 207 kPa (20 to 30 psi). If the discharge pressure (highside) is higher than 1656 kPa (240 psi), check for a restricted discharge line. Also check the engine cooling system for overheating, air trapped in the system, or a faulty fan drive. If the discharge pressure (high side) is less than 966 kPa (140 psi), deck for a faulty compressor. Front And Rear AC 1. Attach a manifold gauge set. Close the vehicle doors and windows, start the engine, and hold the engine speed at 1,000 rpm. Set the heater-A/C mode control switch knob in the recirculation mode (Max A/C) position, the temperature control knob in the full hot position, and both the front and rear blower motor switches in their highest speed positions. Disconnect and plug the vacuum harness connector at the water valve in the engine compartment. Unplug the fin sensing cycling clutch switch wire harness connector. 2. Operate the air conditioning system for at least five minutes to stabilize the system, and to provide sufficient reheat to load the front evaporator and the rear combination coil. The discharge pressure (high side) at the service port should reach 966 to 1656 kPa (140 to 240 psi). If this discharge pressure cannot be obtained, check the refrigerant system charge. See Refrigerant System Charge. WARNING: EXTREME CARE MUST BE USED WHEN HANDLING LIQUID CARBON DIOXIDE (CO2) AS SKIN INJURY CAN OCCUR. PROTECTIVE GLOVES SHOULD BE WORN. 3. Both the front and rear expansion valves should be checked for correct operation. Apply liquid carbon dioxide (CO2) to the front expansion valve control head (completely cover the head) for a minimum of thirty seconds. Remove the rear heater-A/C trim cover and apply liquid carbon dioxide (CO2) to the rear expansion valve control head (completely cover the head) for a minimum of thirty seconds. Grasp the suction line (large line) off the combination coil with a bare hand and hold it for at least two minutes. Use the same procedure with the front expansion valve. Grasp the suction line jumper below the expansion valve (before the rear suction line tee) with a bare hand and hold for at least two minutes. When testing the front expansion valve, place the rear blower motor switch in the Off position. 4. With a correctly operating expansion valve, the suction line will feel warm with the closing of the valve (cold applied). Then the line will cool sharply within two minutes as the valve opens. If this temperature change does not occur, the expansion valve is faulty and must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > Page 5745 Expansion Valve: Service and Repair Front WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the screw that secures the filter-drier to its mounting bracket. Front Expansion Valve Remove/Install 4. Remove the screw that secures the block fitting of the suction line jumper to the expansion valve, and separate the fitting from the expansion valve. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Move the suction line jumper and filter-drier as a unit away from the expansion valve far enough to access the mounting screws. 6. Remove the two screws that secure the expansion valve to the evaporator coil block fitting, and separate the expansion valve from the fitting. Install plugs in, or tape over all of the opened refrigerant line fittings. INSTALLATION 1. Remove the tape or plugs from the evaporator coil block fitting and the evaporator side of the expansion valve. Position the expansion valve to the evaporator coil block fitting and secure the connection with two screws. Tighten the mounting screws to 11.4 N.m (100 in. lbs.). 2. Remove the tape or plugs from the block fitting on the suction line jumper and the expansion valve. Position the suction line jumper block fitting to the expansion valve and secure the connection with a screw. Tighten the mounting screw to 22 N.m (200 in. lbs.). 3. Reinstall the screw that secures the filter-drier to its mounting bracket. Tighten the mounting screw to 8.5 N.m (75 in. lbs.). 4. Connect the battery negative cable. 5. Evacuate the refrigerant system. 6. Charge the refrigerant system. Rear The rear expansion valve is used only on models with the optional rear heater-A/C unit. The expansion valve can be removed without removing the rear heater-A/C unit from the vehicle. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the cover from the rear heater-A/C unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > Page 5746 Rear Expansion Valve Remove/Install 4. Remove the screw from the adapter plate that secures the rear heater-A/C unit liquid and suction lines to the expansion valve. 5. Separate the rear heater-A/C unit liquid and suction lines from the expansion valve. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Remove the two screws that secure the expansion valve to the rear heater-A/C unit combination coil evaporator tube bracket. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the expansion valve from the rear heater-A/C unit. INSTALLATION 1. Remove the tape or plugs from the combination coil evaporator tube bracket and the evaporator side of the expansion valve. Position the expansion valve to the tube bracket and secure the connection with two screws. Tighten the mounting screws to 11.4 N.m (100 in. lbs.). 2. Remove the tape or plugs from the rear heater- A/C unit suction and liquid lines and from the expansion valve. Position the suction and liquid lines to the expansion valve and secure the connection with the adapter plate and mounting screw. Tighten the mounting screw to 22 N.m (200 in. lbs.). 3. Reinstall the cover to the rear heater-A/C unit. See Rear Heater-A/C Cover. 4. Connect the battery negative cable. 5. Evacuate the refrigerant system. 6. Charge the refrigerant system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Heater Control Valve Cable > Component Information > Service and Repair Heater Control Valve Cable: Service and Repair The rear water valve control cable is used only on models with the optional rear heater-A/C unit. The rear water valve control cable can be removed without removing the rear heater-A/C unit from the vehicle. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect the control cable from the rear water valve. 3. Remove the rear mode control motor from the rear heater-A/C unit. Rear Water Valve Control Cable Remove/Install 4. Remove the screw that secures the rear water valve control cable flag retainer to the rear heater-A/C unit upper housing. 5. Remove the water valve control cable adaptor from the rear heat-A/C mode door pivot shaft. 6. Remove the rear water valve control cable and adaptor from the rear heater-A/C unit upper housing. 7. Separate the rear water valve control cable end from the hole on the end of the adaptor lever. INSTALLATION 1. Install the rear water valve control cable end into the hole on the end of the adaptor lever. 2. Position the rear water valve control cable and adaptor to the rear heater-A/C unit upper housing. 3. Install the rear water valve control cable adaptor into the rear heat-A/C mode door pivot shaft. Be certain to index the alignment splines on the adaptor to the spline in the pivot shaft. 4. Install the screw that secures the rear water valve control cable flag retainer to the rear heater-A/C unit upper housing. Tighten the mounting screw to 2.2 N.m (20 in. lbs.). 5. Reinstall the rear mode control motor onto the rear heater-A/C unit. 6. Connect the control cable to the rear water valve. 7. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation Heater Core: Description and Operation SYSTEM OPERATION Front The heater core is located in the heater-A/C housing, on the right side of the engine compartment. It is a heat exchanger made of rows of tubes and fins. Engine coolant is circulated through heater hoses to the heater core whenever the front water valve is open. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend air door allows control of the heater output air temperature by controlling how much of the air flowing through the heater-A/C housing is directed through or around the heater core. The blower motor speed controls the volume of air flowing through the heater-A/C system. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Rear Models equipped with the optional rear heater-A/C unit have a combination coil located within the rear unit housing. The combination coil functions as both the rear heater core and the rear evaporator coil. See Combination Coil in the Description and Operation for more information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 5754 Heater Core: Service and Repair Front REMOVAL 1. Remove the heater-A/C housing from the engine compartment. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair 2. Remove the top cover from the heater-A/C housing. Heater Core Remove/Install 3. Remove the screw that secures the heater core tube support bracket to the mounting boss on the top of the heater-A/C housing. 4. Lift the heater core out of the heater-A/C housing INSTALLATION 1. Insert the heater core into the bottom of the heater-A/C housing. 2. Install the screw that secures the heater core tube support bracket to the mounting boss on the top of the heater-A/C housing. Tighten the mounting screw to 2.2 N.m (20 in. lbs.). 3. Reinstall the top cover to the heater-A/C housing. 4. Reinstall the heater-A/C housing in the engine compartment. Rear The heater core for the optional rear heater-A/C unit is integral with the air conditioning evaporator coil. This unit is referred to as the combination coil. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Rear Heater-A/C Unit Plumbing Heater Hose: Service and Repair Rear Heater-A/C Unit Plumbing The rear heater-A/C unit plumbing is used only on models with the optional rear heater-A/C unit. while the formed metal rear heater-A/C unit suction line, liquid line, and heater lines are available for separate service replacement, the rear heater-A/C unit must be removed from the vehicle in order to service them. The molded and straight heater hoses used on the rear heater-A/C unit can be serviced in the vehicle. Any kinks or sharp bends in the rear heater-A/C unit plumbing will reduce the capacity of the entire heating and air conditioning system. Kinks and sharp bends reduce the system flow. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. High temperature coolant is present in the heater plumbing when the engine is operating. Extreme care must be exercised to make sure that each of the plumbing connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Remove the rear heater-A/C unit from the vehicle. 2. Disconnect the rear heater-A/C unit liquid and suction lines from the expansion valve. See Expansion Valve - Rear replacement procedures. 3. Disconnect the rear heater-A/C unit heater hoses from the heater inlet and outlet lines. Rear Heater-A/c Plumbing Remove/Install 4. Disengage the seal from the plumbing plate, which is secured to the forward outboard corner of the rear heater-A/C unit lower housing. Push the bottom of the seal out through the top of the plumbing plate from underneath. 5. Remove the plumbing lines and seal as an assembly from the rear heater-A/C unit. 6. If the suction line is being serviced, remove the tie-wraps that secure each end of the insulator to the line, then slide the insulator off. 7. Push the line through the hole from the top of the seal, twisting and turning the line as needed, while pulling it from the bottom of the seal. INSTALLATION 1. Push the line through the hole from the bottom of the seal, twisting and turning the line as needed, while pulling it from the top of the seal. 2. If the suction line is being serviced, slide the insulator onto the line, then secure each end of the insulator to the line with a tie-wrap. 3. Position the plumbing lines and seal as an assembly to the rear heater-A/C unit. 4. Reinstall the seal to the plumbing plate. Push the seal into the plumbing plate from the top until it is fully seated. 5. Connect the rear heater-A/C unit heater hoses to the heater inlet and outlet lines. 6. Connect the rear heater-A/C unit liquid and suction lines to the expansion valve. 7. Reinstall the rear heater-A/C unit in the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Rear Heater-A/C Unit Plumbing > Page 5759 Heater Hose: Service and Repair Underbody Plumbing The underbody plumbing lines are used only on models with the optional rear heater-A/C unit. While the underbody suction line, liquid line, and combination heater line are available for separate service replacement, all lines must be removed from the vehicle as a unit for service. Any kinks or sharp bends in the underbody plumbing will reduce the capacity of the entire heating and air conditioning system. Kinks and sharp bends reduce the system flow. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. High temperature coolant is present in the heater plumbing when the engine is operating. Extreme care must be exercised to make sure that each of the plumbing connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 4. From the engine compaftment, disconnect the underbody liquid line at the liquid line extension and the underbody suction line at the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. From the engine compaftment, disconnect the heater supply and return hoses from the underbody combination heater line. 6. Remove the engine cover from the passenger compaftment. 7. Raise and support the vehicle. 8. Disengage the front park brake release cable routing clip from the underbody suction line. Rear Heater-A/C Pluming Connections Remove/Install 9. From under the vehicle, disconnect the flare nut on the underbody liquid line from the threaded 10. From under the vehicle, disconnect the flare nut on the underbody suction line from the threaded fitting on the rear heater-A/C unit suction line. Install plugs in, or tape over all of the opened refrigerant line fittings. 11. From under the vehicle, disconnect the heater supply and return hoses from the rear heater-A/C unit heater lines. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Rear Heater-A/C Unit Plumbing > Page 5760 Underbody Plumbing Remove/Install 12. Remove the nut that secures the underbody plumbing clamp to the front floor panel near the left side of the engine cover opening. 13. Remove the screw that secures the underbody plumbing clamp to the front floor panel reinforcement. 14. Remove the screws that secure the two underbody refrigerant line clamps to the side panel to underbody reinforcement. 15. Remove the underbody plumbing bundle from the vehicle. INSTALLATION 1. From under the vehicle, position the underbody plumbing bundle to the side panel to underbody reinforcement and secure it by loosely installing the two clamp mounting screws. 2. From under the vehicle, connect the heater supply and return hoses to the rear heater-A/C unit heater lines. 3. From under the vehicle, remove the tape or plugs from the suction line fittings at the rear of the underbody plumbing bundle and at the rear heater-A/C unit. Connect the flare nut on the underbody suction line to the threaded fitting on the rear heater-A/C unit suction line. Tighten the fitting to 47 N.m 420 in. lbs. 4. From under the vehicle, remove the tape or plugs from the liquid line fittings at the rear of the underbody plumbing bundle and at the rear heaterA/C unit. Connect the flare nut on the underbody liquid line to the threaded fitting on the rear heaterA/C unit liquid line. Tighten the fitting to 27 N.m 244 in. lbs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation High Pressure Safety Valve HVAC: Description and Operation SYSTEM OPERATION High Pressure Relief Valve The high pressure relief valve is located on the rear surface of the compressor housing. This mechanical valve is designed to vent refrigerant from the system to protect against damage to the compressor and other system components, caused by condenser air flow restriction or an overcharge of refrigerant. The high pressure relief valve vents the system when a discharge pressure of 3445 to 4135 kPa (500 to 600 psi) or above is reached. The valve closes with a minimum discharge pressure of 2756 kPa (400 psi) is reached. The high pressure relief valve vents only enough refrigerant to reduce the system pressure, and then re-seats itself. The majority of the refrigerant is conserved in the system. If the valve vents refrigerant, it does not mean the valve is faulty. On new compressor assemblies, a mylar disc is applied to the venting port of the valve. The disc is primarily intended for protection of the valve during the painting operation. A missing or damaged disc does not indicate failure. If the mylar disc has loosened or come off, apply a drop or two of refrigerant oil into the valve mechanism through the venting holes. This will prevent salt, dirt, or moisture from affecting the operation of the valve. The high pressure relief valve is only serviced as part of the compressor assembly, and must not be removed or otherwise disturbed. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation Hose/Line HVAC: Description and Operation SYSTEM OPERATION Refrigerant Line The refrigerant lines and hoses are used to carry the refrigerant between the various air conditioning system components. A barrier hose design with a nylon tube inner hose liner is used for the R-134a air conditioning system on this vehicle. This nylon liner helps to further contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant hoses are made from lightweight aluminum, and use brazeless fittings. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL IN FORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Remove the radiator grille from the vehicle. Suction And Discharge Line Remove/Install 5. Remove the screw that secures the block fitting on the discharge line to the block fitting on the inlet of the condenser, and separate the fitting from the condenser. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Disconnect the flare nut on the suction line from the threaded fitting on the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 8. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from the refrigerant line fittings on the compressor and the refrigerant line manifold. Install the manifold to the compressor. Tighten the mounting screw to 22 N.m (200 in. lbs.). 2. Remove the tape or plugs from the refrigerant line fittings on the suction line and the suction line jumper. Connect the flare nut on the suction line to the threaded fitting on the suction line jumper. Tighten the fitting to 47 N.m (420 in. lbs.). 3. Remove the tape or plugs from the discharge line block fitting and the inlet of the condenser. Connect the liquid line to the condenser inlet and secure the connection with a screw. Tighten the mounting screw to 22 N.m (200 in. lbs.). 4. Reinstall the radiator grille to the vehicle. 5. Plug in the wire harness connector to the high pressure cut-off switch. 6. Connect the battery negative cable. 7. Evacuate the refrigerant system. 8. Charge the refrigerant system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5769 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Liquid Line Remove/Install 3. Remove the screw that secures the block fitting of the liquid line to the inlet of the filter-drier, and separate the fitting from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Remove the radiator grille from the vehicle. 5. Remove the screw that secures the block fitting on the liquid line to the block fitting on the outlet of the condenser, and separate the fitting from the condenser. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Remove the liquid line from the engine compartment. INSTALLATION 1. Remove the tape or plugs from the liquid line block fitting and the outlet of the condenser. Connect the liquid line to the condenser outlet and secure the connection with a screw. Tighten the mounting screw to 22 N.m (200 in. lbs.). 2. Reinstall the radiator grille to the vehicle. 3. Remove the tape or plugs from the liquid line block fitting and the inlet of the filter-drier. Connect the liquid line to the filter-drier inlet and secure the connection with a screw. Tighten the mounting screw to 13.5 N.m (120 in. lbs.). 4. Connect the battery negative cable. 5. Evacuate the refrigerant system. 6. Charge the refrigerant system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5770 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement Suction and Discharge Line Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL IN FORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Remove the radiator grille from the vehicle. Suction And Discharge Line Remove/Install 5. Remove the screw that secures the block fitting on the discharge line to the block fitting on the inlet of the condenser, and separate the fitting from the condenser. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Disconnect the flare nut on the suction line from the threaded fitting on the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 8. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from the refrigerant line fittings on the compressor and the refrigerant line manifold. Install the manifold to the compressor. Tighten the mounting screw to 22 N.m (200 in. lbs.). 2. Remove the tape or plugs from the refrigerant line fittings on the suction line and the suction line jumper. Connect the flare nut on the suction line to the threaded fitting on the suction line jumper. Tighten the fitting to 47 N.m (420 in. lbs.). 3. Remove the tape or plugs from the discharge line block fitting and the inlet of the condenser. Connect the liquid line to the condenser inlet and secure the connection with a screw. Tighten the mounting screw to 22 N.m (200 in. lbs.). 4. Reinstall the radiator grille to the vehicle. 5. Plug in the wire harness connector to the high pressure cut-off switch. 6. Connect the battery negative cable. 7. Evacuate the refrigerant system. 8. Charge the refrigerant system. Suction Line Jumper Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5771 flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the low pressure cut-off switch from the fitting on the suction line jumper. See Low Pressure Cut-Off Switch Replacement for the procedures. 3. Recover the refrigerant from the refrigerant system. Suction Line Jumper Remove/Install 4. Disconnect the flare nut on the suction line from the threaded fitting on the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. If the vehicle is equipped with the optional rear heater-A/C unit, go to Step 7. If not, go to Step 9. 6. Disconnect the flare nut on the underbody plumbing suction line from the threaded fitting on the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Disconnect the flare nut on the underbody plumbing liquid line from the threaded fitting on the liquid line extension. Install plugs in, or tape over all of the opened refrigerant line fittings. 8. Remove the screw that secures the filter-drier to its mounting bracket. 9. Remove the screw that secures the block fitting of the suction line jumper to the outlet of the filter-drier, and separate the fitting from the fitter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 10. Remove the screw that secures the block fitting of the suction line jumper to the expansion valve, and separate the fitting from the expansion valve. Install plugs in, or tape over all of the opened refrigerant line fittings. 11. Remove the suction line jumper from the engine compartment. INSTALLATION 1. Remove the tape or plugs from the block fitting on the suction line jumper and the expansion valve. Position the suction line jumper block fitting to the expansion valve and secure the connection with a screw. Tighten the mounting screw to 22 N.m (200 in. lbs.). 2. Remove the tape or plugs from the block fitting on the suction line jumper and the outlet of the fitter-drier. Position the outlet of the filter-drier to the suction line jumper block fitting and secure the connection with a screw. Tighten the mounting screw to 13.5 N.m (120 in. lbs.). 3. Reinstall the screw that secures the filter-drier to its mounting bracket. Tighten the mounting screw to 8.5 N.m (75 in. lbs.). 4. If the vehicle is equipped with the optional rear heater-A/C unit, go to Step 6. If not, go to Step 8. 5. Remove the tape or plugs from the refrigerant tine fittings on the underbody plumbing liquid line and the liquid line extension. Connect the flare nut on the underbody plumbing liquid line to the threaded fitting on the liquid line extension. Tighten the fitting to 27 N.m (244 in. lbs.). 6. Remove the tape or plugs from the refrigerant line fittings on the underbody plumbing suction line and the suction line jumper. Connect the flare nut on the underbody plumbing suction line to the threaded fitting on the suction line jumper. Tighten the fitting to 47 N.m (420 in. lbs.). 7. Remove the tape or plugs from the refrigerant line fittings on the suction line and the suction line jumper Connect the flare nut on the suction line to the threaded fitting on the suction line jumper. Tighten the fitting to 47 N.m (420 in. lbs.). 8. Install the low pressure cut-off switch to the fitting on the suction line jumper. See Low Pressure Cut-Off Switch. 9. Connect the battery negative cable. 10. Evacuate the refrigerant system. 11. Charge the refrigerant system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5772 Hose/Line HVAC: Service and Repair Rear Heater-A/C Unit Plumbing The rear heater-A/C unit plumbing is used only on models with the optional rear heater-A/C unit. while the formed metal rear heater-A/C unit suction line, liquid line, and heater lines are available for separate service replacement, the rear heater-A/C unit must be removed from the vehicle in order to service them. The molded and straight heater hoses used on the rear heater-A/C unit can be serviced in the vehicle. Any kinks or sharp bends in the rear heater-A/C unit plumbing will reduce the capacity of the entire heating and air conditioning system. Kinks and sharp bends reduce the system flow. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. High temperature coolant is present in the heater plumbing when the engine is operating. Extreme care must be exercised to make sure that each of the plumbing connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Remove the rear heater-A/C unit from the vehicle. 2. Disconnect the rear heater-A/C unit liquid and suction lines from the expansion valve. 3. Disconnect the rear heater-A/C unit heater hoses from the heater inlet and outlet lines. Rear Heater-A/c Plumbing Remove/Install 4. Disengage the seal from the plumbing plate, which is secured to the forward outboard corner of the rear heater-A/C unit lower housing. Push the bottom of the seal out through the top of the plumbing plate from underneath. 5. Remove the plumbing lines and seal as an assembly from the rear heater-A/C unit. 6. If the suction line is being serviced, remove the tie-wraps that secure each end of the insulator to the line, then slide the insulator off. 7. Push the line through the hole from the top of the seal, twisting and turning the line as needed, while pulling it from the bottom of the seal. INSTALLATION 1. Push the line through the hole from the bottom of the seal, twisting and turning the line as needed, while pulling it from the top of the seal. 2. If the suction line is being serviced, slide the insulator onto the line, then secure each end of the insulator to the line with a tie-wrap. 3. Position the plumbing lines and seal as an assembly to the rear heater-A/C unit. 4. Reinstall the seal to the plumbing plate. Push the seal into the plumbing plate from the top until it is fully seated. 5. Connect the rear heater-A/C unit heater hoses to the heater inlet and outlet lines. 6. Connect the rear heater-A/C unit liquid and suction lines to the expansion valve. 7. Reinstall the rear heater-A/C unit in the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5773 Hose/Line HVAC: Service and Repair Underbody Plumbing The underbody plumbing lines are used only on models with the optional rear heater-A/C unit. While the underbody suction line, liquid line, and combination heater line are available for separate service replacement, all lines must be removed from the vehicle as a unit for service. Any kinks or sharp bends in the underbody plumbing will reduce the capacity of the entire heating and air conditioning system. Kinks and sharp bends reduce the system flow. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. High temperature coolant is present in the heater plumbing when the engine is operating. Extreme care must be exercised to make sure that each of the plumbing connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 4. From the engine compaftment, disconnect the underbody liquid line at the liquid line extension and the underbody suction line at the suction line jumper. See Suction Line Jumper in the Replacement. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. From the engine compaftment, disconnect the heater supply and return hoses from the underbody combination heater line. 6. Remove the engine cover from the passenger compaftment. 7. Raise and support the vehicle. 8. Disengage the front park brake release cable routing clip from the underbody suction line. Rear Heater-A/C Pluming Connections Remove/Install 9. From under the vehicle, disconnect the flare nut on the underbody liquid line from the threaded 10. From under the vehicle, disconnect the flare nut on the underbody suction line from the threaded fitting on the rear heater-A/C unit suction line. Install plugs in, or tape over all of the opened refrigerant line fittings. 11. From under the vehicle, disconnect the heater supply and return hoses from the rear heater-A/C unit heater lines. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5774 Underbody Plumbing Remove/Install 12. Remove the nut that secures the underbody plumbing clamp to the front floor panel near the left side of the engine cover opening. 13. Remove the screw that secures the underbody plumbing clamp to the front floor panel reinforcement. 14. Remove the screws that secure the two underbody refrigerant line clamps to the side panel to underbody reinforcement. 15. Remove the underbody plumbing bundle from the vehicle. INSTALLATION 1. From under the vehicle, position the underbody plumbing bundle to the side panel to underbody reinforcement and secure it by loosely installing the two clamp mounting screws. 2. From under the vehicle, connect the heater supply and return hoses to the rear heater-A/C unit heater lines. 3. From under the vehicle, remove the tape or plugs from the suction line fittings at the rear of the underbody plumbing bundle and at the rear heater-A/C unit. Connect the flare nut on the underbody suction line to the threaded fitting on the rear heater-A/C unit suction line. Tighten the fitting to 47 N.m 420 in. lbs. 4. From under the vehicle, remove the tape or plugs from the liquid line fittings at the rear of the underbody plumbing bundle and at the rear heaterA/C unit. Connect the flare nut on the underbody liquid line to the threaded fitting on the rear heaterA/C unit liquid line. Tighten the fitting to 27 N.m 244 in. lbs. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation Housing Assembly HVAC: Service and Repair Heater-A/C Housing Removal and Installation WARNING: - REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT PERFORMING THE FOLLOWING OPERATION. - ON VEHICLES EQUIPPED WITH AIRBAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is not equipped with air conditioning, go to Step 6. If the vehicle is equipped with air conditioning, disconnect the suction line jumper at the expansion valve. 3. Remove the screws that secure the filter-drier and its mounting bracket to the heater-A/C housing and the cowl side panel. Swing the filter-drier, mounting bracket and refrigerant plumbing as a unit out of the way towards the center of the vehicle. 4. Unplug the wire harness connector from the fin sensing cycling clutch switch. 5. Unplug the wire harness connectors from the blower motor resistor, and the high speed blower motor relay 6. Place waterproof material over the generator, to protect it from spilled engine coolant. 7. Drain the engine cooling system. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 8. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes. Heater-A/C Housing Remove/Install 9. Remove the right headlamp assembly, the grille panel, the right cowl grille support panel, and the right radiator core support assembly. 10. Remove the two screws that secure the lower heater-A/C housing flange to the blower housing. 11. Disconnect the link from the blend-air door motor on the top of the distribution duct in the passenger compartment. 12. From the passenger compartment, reach through the instrument panel glove box opening to access and remove the two stamped nuts and one screw that secure the heater-A/C housing to the dash panel below the distribution duct. 13. From the passenger compartment, reach through the instrument panel glove box opening to access and remove the two stamped nuts that secure the heater-A/C housing to the dash panel above the distribution duct. 14. From the engine compartment, remove the one stamped nut that secures the heater-A/C housing to the stud on the dash panel. 15. Carefully separate the lower heater-A/C housing flange from the blower housing. 16. Pull the heater-A/C housing away from the dash panel until the blend-air door link is clear of the hole in the dash panel. 17. Remove the heater-A/C housing from the engine compartment. Disassembly Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 5779 1. Place the heater-A/C housing on a work bench, with the heater-A/C housing top cover facing up. Blend-Air Door Linkage 2. Remove the nut that secures the lever to the blend-air door pivot shaft. 3. Disengage the boot for the blend-air door link from the rear mounting flange of the heater-A/C housing. 4. Remove the blend-air door link, boot and lever from the heater-A/C housing as a unit. Heater-A/C Housing Top Cover Remove/Install 5. Remove the screw that secures the high speed blower motor relay mounting bracket to the heater-A/C housing and remove the relay and bracket. 6. Remove the screws that secure the top cover to the heater-A/C housing. 7. Remove the top cover from the heater-A/C unit. Inspection Examine all of the heater-A/C housing seals for damage. Replace all damaged or deformed seals. Clean all of the heater-A/C mounting flanges and apply new sealant prior to reassembly. Inspect the evaporator coil and heater core for bent fins or other damage. Remove any foreign material or other restrictions to air flow. Repair or replace any faulty or damaged components as required. Assembly 1. Position the top cover onto the heater-A/C unit. Be certain that the blend-air door pivots, all seals, and the grommet for the fin sensing cycling clutch switch wire harness are properly positioned. 2. Secure the top cover to the heater-A/C housing with screws. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 3. Rotate the blend-air door pivot shaft back and forth to confirm that the door moves freely throughout its travel. If there is any binding or interference, remove the top cover from the heater-A/C housing and repair as required. 4. Reinstall the blend-air door lever, link, and boot unit to the heater-A/C housing. Be certain that the boot flange is properly seated in the hole on the rear mounting flange of the housing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 5780 5. Reinstall the lever to the blend-air door pivot shaft and secure it to the shaft with a nut. 6. Position the high speed blower motor relay and mounting bracket to the heater-A/C housing and secure it with a screw. Tighten the mounting screw to 2.2 N.m (20 in. lbs.). INSTALLATION 1. Position the heater-A/C housing to the dash panel. Be certain that the blend-air door link and the housing studs are inserted through the proper holes in the dash panel. 2. Secure the lower heater-A/C housing flange to the blower housing with two screws. Tighten the mounting screws to 2.7 N.m (24 in. lbs.). 3. Secure the heater-A/C unit to the stud on the engine compartment side of the dash panel with a nut. Tighten the mounting nut to 4.5 N.m (40 in. lbs.). 4. From the passenger compartment, reach through the instrument panel glove box opening to install the two nuts that secure the heater-A/C housing studs on the dash panel above the distribution duct. Tighten the mounting nuts to 4.5 N.m (40 in. lbs.). 5. From the passenger compartment, reach through the instrument panel glove box opening to install the two nuts and the screw that secure the heater-A/C housing to the dash panel below the distribution duct. Tighten the mounting nuts to 4.5 N.m (40 in. lbs.). Tighten the mounting screw to 2.7 N.m (24 in. lbs.). 6. Connect the link to the blend-air door motor. See Blend-Air Door Motor Replacement for the procedures. 7. Reinstall the right radiator core support assembly, the right cowl grille support panel, the grille panel, and the right headlamp assembly. 8. Unplug or remove the tape from the heater core tubes. Connect the heater hoses to the heater core tubes and fill the engine cooling system. 9. Plug in the wire harness connectors to the blower motor resistor and the high speed blower motor relay. 10. If the vehicle is not equipped with air conditioning, go to Step 14. If the vehicle is equipped with air conditioning, plug in the wire harness connector to the fin sensing cycling clutch switch. 11. Reconnect the suction line jumper to the expansion valve. 12. Reinstall the screws that secure the filter-drier and its mounting bracket to the cowl side panel and the heater-A/C housing. 13. Connect the battery negative cable. 14. Start the engine and check for proper operation of the heating and air conditioning systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 5781 Housing Assembly HVAC: Service and Repair Rear Heater-A/C Unit Replacement and Service REMOVAL 1. Remove the rear bench seat from the passenger compartment, if the vehicle is so equipped. Rear Heater-A/C Cover Remove/Install 2. Remove the three screws that secure the cover to the rear heater-A/C unit. 3. Remove the cover from the rear heater-A/C unit. INSTALLATION 1. Position the cover over the rear heater-A/C unit. 2. Install the three screws that secure the cover to the rear heater-A/C unit. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 3. Reinstall the rear bench seat to the passenger compartment, if the vehicle is so equipped. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect the underbody plumbing at the rear heater-A/C unit plumbing connections. See Underbody Plumbing Replacement procedures. Install plugs in, or tape over all of the opened plumbing fittings. Rear Heater-A/C Unit Plumbing Plate Remove/Install 3. Remove the three nuts that secure the rear heater-A/C unit plumbing plate studs to the underbody panel. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 5782 Rear Heater-A/C Unit Remove/Install 4. Remove the one screw that secures the rear heater-A/C unit to the underbody panel from underneath. 5. Lower the vehicle and remove the cover from the rear heater-A/C unit. See Rear Heater-A/C Cover Replacement Procedures. 6. Remove the vertical duct from the rear heater-A/C unit. See Ducts and Outlets - Vertical Duct Replacement procedures. 7. Remove the horizontal duct from the rear heater-A/C unit. See Ducts and Outlets - Horizontal Duct Replacement procedures. 8. Remove the screw that secures the rear heater-A/C unit ground wire eyelet to the left side panel strainer behind the unit. 9. Remove the two screws that secure the bottom of the rear heater-A/C unit to the underbody panel. 10. Lift the rear heater-A/C unit upwards far enough for the plumbing to clear the hole in the underbody panel, then pull the unit away from the side panel far enough to access and unplug the wire harness connector from the body wire harness near the front of the unit. 11. Remove the rear heater-A/C unit from the passenger compartment. Disassembly 1. Lift the two relay wire harness connectors upward to disengage them from the mounting tabs on the rear of the rear heater-A/C unit housing. 2. Unplug the wire harness connectors from the rear heater-A/C unit blower motor and the rear mode control motor. 3. Disengage the blower motor cooling tube from the nipple on the lower housing of the rear heater- A/C unit. 4. Remove the control cable from the rear heater-A/C unit water valve. See Water Valve Replacement. Rear Heater-A/C Unit Housing Clip 5. Remove the clip on the rear inboard corner of the rear heater-A/C unit that secures the upper housing to the lower housing. 6. Remove the six screws that secure the upper housing of the rear heater-A/C unit to the lower housing. 7. Remove the upper housing from the rear heater-A/C unit. Inspection Inspect the combination coil for bent fins or other damage. Remove any foreign material or other restrictions to air flow. Repair or replace any faulty or damaged components as required. Clean any foreign material from all of the mating edges of the upper and lower rear heater-A/C unit housing halves prior to reassembly. Assembly 1. Position the upper housing over the lower housing of the rear heater-A/C unit. Be certain that the mating edges of the upper housing are engaged in the channel on the edges of the lower housing. 2. Secure the upper housing to the lower housing of the rear heater-A/C unit with six screws. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 3. Reinstall the clip on the rear inboard corner of the rear heater-A/C unit that secures the upper housing to the lower housing. 4. Reinstall the control cable to the rear heater-A/C unit water valve. See Water Valve - Rear Replacement for the procedures. 5. Reinstall the blower motor cooling tube over the nipple on the lower housing of the rear heater- A/C unit. 6. Plug in the wire harness connectors for the rear heater-A/C unit blower motor and the rear mode control motor. 7. Slide the two relay wire harness connectors downward over the mounting tabs on the rear of the rear heater-A/C unit housing. Be certain that the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 5783 two connectors are interlocked with each other before trying to reinstall them to the mounting tabs on the housing. INSTALLATION 1. Position the rear heater-A/C unit in the passenger compartment. Be certain that the stud on the plumbing plate are inserted through the proper holes in the underbody panel. 2. Plug in the rear heater-A/C unit wire harness connector to the body wire harness. 3. Secure the rear heater-A/C unit to the underbody panel with two screws. Tighten the mounting screws to 1.9 N.m (17 in. lbs.). 4. Secure the rear heater-A/C unit ground wire eyelet to the left side panel strainer behind the unit. Tighten the mounting screw to 1.9 N.m (17 in. lbs.). 5. Reinstall the horizontal duct to the rear heater-A/C unit. See Ducts and Outlets - Horizontal Duct Replacement for the procedures. 6. Reinstall the vertical duct to the rear heater-A/C unit. See Ducts and Outlets - Vertical Duct Replacement for the procedures. 7. Reinstall the cover to the rear heater-A/C unit. See Rear Heater-A/C Cover replacement procedures. 8. Raise and support the vehicle. 9. From underneath the vehicle, reinstall the one screw that secures the rear heater-A/C unit to the underbody panel. Tighten the mounting screw to 1.9 N.m (17 in. lbs.). 10. Reinstall the three nuts that secure the rear heater-A/C unit plumbing plate to the underbody panel. Tighten the mounting nuts to 11.2 N.m (100 in. lbs.). 11. Remove the tape or plugs from all of the plumbing connections. Connect the underbody plumbing to the rear heater-A/C unit plumbing. See Underbody Plumbing Replacement for the procedures. 12. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation Receiver Dryer: Description and Operation SYSTEM OPERATION A single filter-drier unit is used for both the front-only A/C system, and for the combined front and rear A/C system. The filter-drier is mounted on the right side of the engine compartment in front of the heater-A/C housing. It is located in the liquid line between the condenser outlet and the evaporator inlet. Refrigerant enters the filter-drier as a high- pressure, high-temperature liquid. The filter-drier performs a filtering action to prevent foreign material in the refrigerant from contaminating the expansion valve. A desiccant bag is mounted inside the filter-drier canister to absorb any moisture which may have entered and become trapped within the refrigerant system. In addition, during periods of high demand air conditioner operation, the filter-drier acts as a reservoir to store surplus liquid refrigerant. The filter-drier cannot be repaired. If the filter-drier is faulty or damaged, if the refrigerant system has been contaminated, or if the system has been left open to the atmosphere for an indeterminable period, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 5787 Receiver Dryer: Service and Repair WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Filter-Drier Remove/Install 3. Remove the screw that secures the filter-drier to its mounting bracket. 4. Remove the screw that secures the liquid line block fitting to the filter-drier inlet. Separate the liquid line block fitting from the filter-drier inlet. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the screw that secures the filter-drier outlet to the suction line jumper block fitting. Separate the filter-drier outlet from the suction line jumper block fitting. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Remove the filter-drier from the engine compartment. INSTALLATION 1. Remove the tape or plugs from the suction line jumper block fitting and the filter-drier outlet. Position the filter-drier outlet to the suction line jumper block fitting and secure the connection with a screw. Tighten the mounting screw to 13.5 N.m (120 in. lbs.). 2. Remove the tape or plugs from the liquid line block fitting and the filter-drier inlet. Position the liquid line block fitting to the filter-drier inlet and secure the connection with a screw. Tighten the mounting screw to 13.5 N.m (120 in. lbs.). 3. Reinstall the screw that secures the filter-drier to its mounting bracket. Tighten the mounting screw 8.5N.m (75 in. lbs.). 4. Connect the battery negative cable. 5. Evacuate the refrigerant system. 6. Charge the refrigerant system. NOTE: If the filter-drier is replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Single Capacity ........................................................................................................................................................... 0.96 kg (33.86 oz. or 2.12 lbs) R134a Dual Capacity ............................................................................................................................................................. 1.30 kg (45.85 oz. or 2.87 lbs) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 5792 Refrigerant: Fluid Type Specifications Hydrofluorocarbon (HFC), ................................................................................................................... ............................................... R-134a liquefied gas Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 5793 Refrigerant: Description and Operation SYSTEM OPERATION The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 added to an R-134a refrigerant system will cause compressor failure, refrigerant oil sludge or poor air conditioning system performance. In addition, the PolyAlkylene Glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the compressor identifying to service technicians that the air conditioning system is equipped with R-134a. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Description and Operation Refrigerant Filter: Description and Operation SYSTEM OPERATION A single filter-drier unit is used for both the front-only A/C system, and for the combined front and rear A/C system. The filter-drier is mounted on the right side of the engine compartment in front of the heater-A/C housing. It is located in the liquid line between the condenser outlet and the evaporator inlet. Refrigerant enters the filter-drier as a high-pressure, high-temperature liquid. The filter-drier performs a filtering action to prevent foreign material in the refrigerant from contaminating the expansion valve. A desiccant bag is mounted inside the filter-drier canister to absorb any moisture which may have entered and become trapped within the refrigerant system. In addition, during periods of high demand air conditioner operation, the filter-drier acts as a reservoir to store surplus liquid refrigerant. The filter-drier cannot be repaired. If the filter-drier is faulty or damaged, if the refrigerant system has been contaminated, or if the system has been left open to the atmosphere for an indeterminable period, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Description and Operation > Page 5797 Refrigerant Filter: Service and Repair WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Filter-Drier Remove/Install 3. Remove the screw that secures the filter-drier to its mounting bracket. 4. Remove the screw that secures the liquid line block fitting to the filter-drier inlet. Separate the liquid line block fitting from the filter-drier inlet. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the screw that secures the filter-drier outlet to the suction line jumper block fitting. Separate the filter-drier outlet from the suction line jumper block fitting. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Remove the filter-drier from the engine compartment. INSTALLATION 1. Remove the tape or plugs from the suction line jumper block fitting and the filter-drier outlet. Position the filter-drier outlet to the suction line jumper block fitting and secure the connection with a screw. Tighten the mounting screw to 13.5 N.m (120 in. lbs.). 2. Remove the tape or plugs from the liquid line block fitting and the filter-drier inlet. Position the liquid line block fitting to the filter-drier inlet and secure the connection with a screw. Tighten the mounting screw to 13.5 N.m (120 in. lbs.). 3. Reinstall the screw that secures the filter-drier to its mounting bracket. Tighten the mounting screw 8.5N.m (75 in. lbs.). 4. Connect the battery negative cable. 5. Evacuate the refrigerant system. 6. Charge the refrigerant system. NOTE: If the filter-drier is replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System ........................................................................................................................................ ........................................ (Front only) 236 ml 8.0 oz. Total System ........................................................................................................................................ .................................. (Front & Rear) 295 ml 10.0 oz. Condenser ........................................................................................................................................... ................................................................ 30 ml 1.0 oz. Evaporator ........................................................................................................................................... ............................................................... 60 ml 2.0 oz. Filter-Drier ...................................................... ................................................................................................................................................... 30 ml 1.0 oz. Compressor ............................................................................................................................................. Drain and measure the oil from the old compressor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 5802 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. ......................................................................... SP-10 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 5803 Refrigerant Oil: Service and Repair Refrigerant Oil Level Refrigerant Oil Capacities When an air conditioning system is assembled at the factory, all components except the compressor and the combination coil, if the vehicle is so equipped, are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the compressor and the combination coil is dispersed throughout the refrigerant system. The combination coil, evaporator, filter-drier, condenser, and compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of oil in the refrigerant system. This ensures proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the air conditioning system. It will not be necessary to check the oil level in the compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when a filter-drier, evaporator coil, combination coil, or condenser are replaced. See the Refrigerant Oil Capacities chart. When a compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation High Pressure Sensor / Switch: Description and Operation SYSTEM OPERATION High Pressure Cut-Off Switch The high pressure cut-off switch is located on the discharge line near the condenser. The switch is screwed onto a fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The discharge line fitting is equipped with an 0-ring to seal the switch connection. The high pressure cut-off switch is connected in series electrically with the low pressure cut-off switch between the fin sensing cycling clutch switch and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch on and off. This prevents compressor operation when the discharge line pressure approaches high levels. The high pressure cut-off switch contacts are open when the discharge line pressure rises above about 3100 to 3375 kPa (450 to 490 psi). The switch contacts will close when the discharge line pressure drops to about 1860 to 2275 kPa (270 to 330 psi). The high pressure cut-off switch is a factory-calibrated unit. The switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Page 5808 High Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the high pressure cut-off switch, verify that the refrigerant system has the correct refrigerant charge. See Refrigerant System Charge in the Service Procedures. 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the high pressure cut-off switch on the refrigerant system fitting. 3. Check for continuity between the two terminals of the high pressure cut-off switch. There should be continuity. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Page 5809 High Pressure Sensor / Switch: Service and Repair REMOVAL High Pressure Cut-Off Switch Removed/Install 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the high pressure cut-off switch, which is mounted to a fitting on the discharge line between the compressor and the condenser inlet. 3. Unscrew the high pressure cut-off switch from the discharge line fitting. 4. Remove the high pressure cut-off switch from the vehicle. 5. Remove the 0-ring seal from the discharge line fitting and discard. INSTALLATION 1. Lubricate a new 0-ring seal with clean refrigerant oil and install it on the discharge line fitting. Use only the specified 0-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the high pressure cut-off switch on the discharge line fitting. Tighten the switch to 7.5 N.m (5.5 ft. lbs.). 3. Plug the wire harness connector into the high pressure cut-off switch. 4. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams 8w-80-4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 5813 Low Pressure Sensor / Switch: Description and Operation SYSTEM OPERATION Fin Sensing Cycling Clutch Switch Fin Sensing Cycling Clutch Switch The fin sensing cycling clutch switch is used on this model to signal the Powertrain Control Module (PCM) to cycle the compressor clutch on arid off in order to control the evaporator temperature. Controlling the evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The fin sensing cycling clutch switch consists of a probe and a switch unit. The probe, which is a Negative Temperature Coefficient (NTC) thermistor in a capillary tube, is inserted between the front evaporator coil fins to monitor evaporator temperature. The switch unit contains internal control logic that monitors the input from the probe in order to switch an internal transistor that controls the output to the PCM. when the fin sensing cycling clutch switch sees a temperature input below about 1.60 °C (350 °F), it signals the PCM to cycle the compressor off. When the temperature input reaches above about 3.90 °C (390 °F), the switch signals the PCM to cycle the compressor back on. The fin sensing cycling clutch switch can be accessed for service by removing the screws and carefully lifting the front of the top cover up from the heater-A/C housing. The fin sensing cycling clutch switch is a sealed unit and cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Testing and Inspection > Fin Sensing Cycling Clutch Switch Low Pressure Sensor / Switch: Testing and Inspection Fin Sensing Cycling Clutch Switch Before testing the fin sensing cycling clutch switch, verity that the refrigerant system has the correct refrigerant charge. Also check that both the low and high pressure cut-off switches are functional, and confirm that the compressor clutch is operational. Use a volt/ohmmeter to test the switch. 1. Turn the ignition switch in the On position. Place the heater-A/C mode control switch in any A/C position. Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the fill sensing cycling clutch switch wire harness connector. If OK, go to Step 3. If not OK, repair the open circuit to the fuse in the junction block as required. 2. With the ambient temperature between 20 to 30° C (68 to 900 F), start the engine and run the air conditioning system. The compressor clutch should cycle on and off two to three times per minute. If the clutch fails to cycle at this rate in these temperatures, replace the faulty fin sensing cycling clutch switch. NOTE: If the ambient temperature is above 32° C (90° F) the compressor clutch may stay engaged and not cycle due to the high heat load. This condition is normal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Testing and Inspection > Fin Sensing Cycling Clutch Switch > Page 5816 Low Pressure Sensor / Switch: Testing and Inspection Low Pressure Cut-Off Switch Before performing diagnosis of the low pressure cut-off switch, remember that lower ambient temperatures, below about -1° C (30° F), during cold weather will open the switch contacts and prevent compressor operation due to the pressure/temperature relationship of the refrigerant. Also verify that the refrigerant system has the correct refrigerant charge. See Refrigerant System Charge in the Service Procedures. 1. Disconnect and isolate the battery negative cable. 2. Unplug the low pressure cut-off switch wire harness connector from the switch on the suction line jumper fitting. 3. Install a jumper wire between the two cavities of the low pressure cut-off switch wire harness connector. 4. Connect a manifold gauge set to the refrigerant system service ports. See Refrigerant System Service Equipment and Refrigerant System Service Ports. 5. Connect the battery negative cable. 6. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 7. Check for continuity between the two terminals of the low pressure cut-off switch. There should be continuity with a suction pressure (low side) reading of 103 to 172 kPa (15 to 25 psi) or above, arid no continuity with a suction pressure reading of 48 to 90 kPa (7 to 13 psi) or below. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Fin Sensing Cycling Clutch Switch Replacement Low Pressure Sensor / Switch: Service and Repair Fin Sensing Cycling Clutch Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the screws that secure the top cover of the heater-A/C housing to the housing. 3. Unplug the wire harness connector from the fin sensing cycling clutch switch. Fin Sensing Cycling Clutch Switch Remove/Install 4. Carefully lift the front of the heater-A/C housing top cover far enough to access and remove the fin sensing cycling clutch switch probe from the evaporator coil fins. INSTALLATION 1. Carefully lift the heater-A/C housing top cover far enough to insert the fin sensing cycling clutch switch probe into the same hole between the evaporator coil fins from which it was removed. 2. Position the grommet on the fin sensing cycling clutch switch wire harness into the notch on the front edge of the lower heater-A/C housing. 3. Secure the top cover to the heater-A/C housing with the mounting screws. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 4. Plug in the fin sensing cycling clutch switch wire harness connector. 5. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Fin Sensing Cycling Clutch Switch Replacement > Page 5819 Low Pressure Sensor / Switch: Service and Repair Low Pressure Cut-Out Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Low Pressure Cut-Off Switch Remove/Install 2. Unplug the wire harness connector from the low pressure cut-off switch on the suction line jumper near the filter-drier. 3. Unscrew the low pressure cut-off switch from the fitting on the suction line jumper. 4. Remove the 0-ring seal from the suction line jumper fitting and discard. INSTALLATION 1. Lubricate a new 0-ring seal with clean refrigerant oil and install it on the suction line jumper fitting. Use only the specified 0-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the low pressure cut-off switch on the suction line jumper fitting. Tighten the switch to 4 N.m (2.9 ft. lbs.). 3. Plug the wire harness connector into the low pressure cut-off switch. 4. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Blower Motor Relay Blower Motor Relay: Description and Operation Blower Motor Relay SYSTEM OPERATION Front The front blower motor relay is a International Standards Organization (ISO)-type relay. The relay is a electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) directly to the blower motor. The relay is energized when the relay coil is provided a voltage signal by the ignition switch. This arrangement reduces the amount of battery current that must flow through the ignition switch. The blower motor relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motor receives no battery current. See Blower Motor Relay in the Diagnosis and Testing for more information. The front blower motor relay is located in the PDC in the engine compartment. Refer to the PDC label for blower motor relay identification and location. The blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Rear The blower motor relay for the optional rear heater-A/C unit is a International Standards Organization (ISO)-type relay. The relay is a electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) directly to the blower motor. The relay is energized when the relay coil is provided a voltage signal by the ignition switch. This arrangement reduces the amount of battery current that must flow through the ignition switch. The blower motor relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motor receives no battery current. See Blower Motor Relay in the Diagnosis and Testing for more information. The rear blower motor relay is located in a connector that is secured to the back of the rear heater-A/C unit housing in the passenger compartment. See Blower Motor Relay - Rear in the Removal and Installation for rear blower motor relay identification and location. The blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Blower Motor Relay > Page 5826 Blower Motor Relay: Description and Operation High Speed Blower Motor Relay SYSTEM OPERATION Front The front blower motor electrical circuit uses a high speed blower motor relay. The high speed blower motor relay is a International Standards Organization (1S0)-type relay The relay is a electromechanical device that switches the blower motor to ground, bypassing the remainder of the blower motor feed circuit. The high speed blower motor relay is energized when the relay coil is provided a ground signal by the blower motor switch, and a battery feed from the ignition switch. When the relay is de-energized, the front blower motor ground feed is routed through the front blower motor switch and the blower motor resistor. See High Speed Blower Motor Relay in the Diagnosis and Testing for more information. The front high speed blower motor relay is located in the engine compartment, on a bracket that is secured under one of the screws for the top cover on the inboard side of the heater-A/C housing. The high speed blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Rear The optional rear heater-A/C unit blower motor electrical circuit uses a high speed blower motor relay The high speed blower motor relay is a International Standards Organization (IS0)-type relay The relay is a electromechanical device that switches the blower motor to ground, bypassing the remainder of the blower motor feed circuit. The high speed blower motor relay is energized when the relay coil is provided a ground signal by the blower motor switch, and a battery feed from the ignition switch. When the relay is de-energized, the rear blower motor ground feed is routed through the rear blower motor switch and the blower motor resistor. See High Speed Blower Motor Relay in the Diagnosis and Testing for more information. The rear high speed blower motor relay is located in a connector that is secured to the back of the rear heater-A/C unit housing in the passenger compartment. See High Speed Blower Motor Relay Rear in the Removal and Installation for rear high speed blower motor relay identification and location. The rear high speed blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay Blower Motor Relay: Testing and Inspection Blower Motor Relay Blower Motor Relay Relay Test The blower motor relays used for the front heater-only or heater-A/C systems and for the optional rear heater-A/C unit can be tested in the same manner. The front blower motor relay is located in the Power Distribution Center (PDC). The rear blower motor relay is located in a connector that is attached to the back of the rear heater-A/C unit. See Blower Motor Relay in the Removal and Installation for the procedures to remove the relay, to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to fused battery feed directly from a fuse in the Power Distribution Center (PDC), and should be hot at all times. Check for battery voltage at the PDC cavity for relay terminal 30. If OK, go to Step 3. If not OK repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 4. 3. The relay normally open terminal cavity (87) is connected to the blower motor. When the relay is energized, terminal 87 is connected to terminal 30 and provides full battery current to the blower motor feed circuit. There should be continuity between the PDC cavity for terminal 87 and the blower motor relay output circuit cavity of the blower motor wire harness connector at all times. If OK, go to Step 5. If not OK, repair the open circuit to the blower motor as required. 4. The coil battery terminal cavity (86) is connected to the ignition switch. When the ignition switch is placed in the On position, fused ignition switch output is directed from a fuse in the junction block to the relay electromagnetic coil to energize the relay. There should be battery voltage at the PDC cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 6. If not OK, repair the open circuit to the junction block fuse as required. 5. The coil ground terminal cavity (85) is connected to ground. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the PDC cavity for relay terminal 85 and a good ground at all times. If not OK, repair the open circuit as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 5829 Blower Motor Relay: Testing and Inspection High Speed Blower Motor Relay Blower Motor Relay Relay Test The high speed blower motor relays used for the front heater-only or heater-A/C systems and for the optional rear heater-A/C unit can be tested in the same manner. The front high speed blower motor relay is located in the engine compartment on a bracket mounted to the inboard side of the heater-A/C housing. The rear high speed blower motor relay is located in a connector that is attached to the back of the rear heater-A/C unit. See Blower Motor Relay in the Removal and Installation procedures to remove the relay, to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the ground side of the front or rear blower motor. There should be continuity between the ground circuit cavity of the front or rear blower motor wire harness connector and the wire harness connector cavity for relay terminal 30 at all times. If OK, go to Step 3. If not OK, repair the open circuit to the front or rear blower motor as required. 2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 4. 3. The relay normally open terminal cavity (87) is connected to ground. When the relay is energized, terminal 87 is connected to terminal 30 and provides a direct path to ground for the front or rear blower motor. There should be continuity between the wire harness connector cavity for relay terminal 87 and ground at all times. If OK, go to Step 5. If not OK, repair the open circuit to ground as required. 4. The coil battery terminal cavity (86) is connected to the ignition switch. When the ignition switch is placed in the On position, fused ignition switch output is directed from a fuse in the junction block to the relay electromagnetic coil to energize the relay. There should be battery voltage at the wire harness connector cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 6. If not OK, repair the open circuit to the junction block fuse as required. 5. The coil ground terminal cavity (85) is connected to the high speed output circuit terminal of the front or rear blower motor switch. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the wire harness connector cavity for relay terminal 85 and the high speed output circuit terminal of the front or rear blower motor switch at all times. If not OK, repair the open circuit to the front or rear blower motor switch as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Page 5830 Blower Motor Relay: Service and Repair Front 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for blower motor relay identification and location. 4. Unplug the blower motor relay from the PDC. 5. Install the blower motor relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Rear The rear blower motor relay is used only on models with the optional rear heater-A/C unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the rear heater-A/C unit. Rear Blower Motor Relay Remove/Install 3. Unplug the blower motor relay from the inboard relay wire harness connector, which is secured to the rear of the rear heater-A/C unit. 4. Install the blower motor relay by aligning the relay terminals with the cavities in the wire harness connector and pushing the relay firmly into place. 5. Reinstall the cover for the rear heater-A/C unit. 6. Connect the battery negative cable. 7. Test the relay operation. High Speed Blower Motor Relay Front 1. Disconnect and isolate the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Page 5831 Front High Speed Blower Motor Relay Remove/Install 2. The high speed blower motor relay is retained by a snap fit to the blade of the mounting bracket on the inboard side of the heater-A/C housing. Unsnap the relay from the mounting bracket by sliding it downwards. 3. Unplug the wire harness connector from the high speed blower motor relay. 4. Install the high speed blower motor relay by aligning the relay terminals with the cavities in the relay wire harness connector and pushing the relay firmly into place. 5. Slide the molded receptacle on the high speed blower motor relay case back onto the blade of the mounting bracket until it snaps into place. 6. Connect the battery negative cable. 7. Test the relay operation. Rear The rear high speed blower motor resistor is used only on models with the optional rear heater-A/C unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the rear heater-A/C unit. Rear High Speed Blower Motor Relay Remove/Install 3. Unplug the high speed blower motor relay from the outboard relay wire harness connector, which is secured to the rear of the rear heater-A/C unit. 4. Install the high speed blower motor relay by aligning the relay terminals with the cavities in the wire harness connector and pushing the relay firmly into place. 5. Reinstall the cover for the rear heater-A/C unit. 6. Connect the battery negative cable. 7. Test the relay operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations Compressor Clutch Relay: Component Locations 8w-10-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 5836 A/C Compressor Clutch Relay Connector, PDC. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 5837 A/C Compressor Clutch Relay Connector, PDC. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5838 Compressor Clutch Relay: Description and Operation SYSTEM OPERATION The compressor clutch relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The compressor clutch relay is a electromechanical device that switches battery current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay. The PCM responds to inputs from the heater-A/C mode control switch, the low pressure cut-off switch, the high pressure cut-off switch, and the fin sensing cycling clutch switch. See Compressor Clutch Relay in the Diagnosis and Testing for more information. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5839 Compressor Clutch Relay: Testing and Inspection Relay Test Compressor Clutch Relay The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 3. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 4. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 5. If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 6. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5840 Compressor Clutch Relay: Service and Repair Power Distribution Center REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug the compressor clutch relay from the PDC. 5. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation SYSTEM OPERATION Front The front blower motor is controlled by a four position rotary-type blower motor switch, mounted in the heater-only or heater-A/C control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned off by selecting the Off position with the heater-A/C mode control switch knob. The blower motor switch directs the blower motor ground path from the mode control switch to the blower motor resistor, or directly to ground through the high speed blower motor relay, as required to achieve the selected blower motor speed. The front blower motor switch cannot be repaired and, if faulty or damaged, the entire heater-only or heater-A/C control unit must be replaced. The blower motor switch knob is serviced separately Rear The optional rear heater-A/C unit blower motor is controlled by a four position rotary-type blower motor switch, mounted in the accessory switch plate located to the right of the heater-A/C control on the instrument panel. The switch allows the selection of one of three blower motor speeds and an Off position. The rear blower motor switch directs the blower motor ground path to the blower motor resistor, or directly to ground through the high speed blower motor relay as required to achieve the selected blower motor speed. The rear blower motor switch cannot be repaired and, if faulty or damaged, it must be replaced. The rear blower motor switch knob is serviced separately The rear blower motor switch also has a replaceable incandescent-type illumination lamp bulb. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 5845 Blower Motor Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR-BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Front 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the heater-A/C control from the instrument panel. See Heater-A/C Control Replacement for the procedures. Check for continuity between the ground circuit (Z1V) cavity of the heater-A/C mode control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 2. With the heater-A/C control wire harness connector unplugged, place the heater-A/C mode control switch knob in any position except the Off position. Check for continuity between the two ground circuit terminals in the mode switch receptacle of the heater-A/C control. There should be continuity. If OK, go to Step 4. If not OK, replace the faulty heater-A/C control unit. 3. Check for continuity between the ground circuit (C 72) cavities of the heater-A/C mode control wire harness connector and the heater-A/C blower speed switch wire harness connector. There should be continuity. If OK, go to Step 5. If not OK, repair the open circuit as required. 4. Check for continuity between the ground circuit (C 72) terminal and each of the blower motor driver circuit terminals in the blower speed switch receptacle of the heater-A/C control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the heater-A/C control blower speed switch wire harness connector and the front blower motor resistor or the front high speed blower motor relay as required. If not OK, replace the faulty heater-A/C control unit. Rear 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the accessory switch plate from the instrument panel. Refer to Accessory Switch Plate in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel for the procedures. Check for continuity between the ground circuit cavity of the rear blower motor switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 2. With the rear blower motor switch wire harness connector unplugged, place the rear blower motor switch knob in any position except the Off position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the rear blower motor switch as you move the blower motor switch knob to each of the three speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the rear blower driver circuits between the rear blower motor switch wire harness connector and the rear blower motor resistor or the rear high speed blower motor relay as required. If not OK, replace the faulty rear blower motor switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 5846 Blower Motor Switch: Service and Repair The rear blower motor switch is used only on models with the optional rear heater-A/C unit. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the accessory switch plate from the instrument panel. Refer to Accessory Switch Plate in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel procedures. Rear Blower Motor Remove/Install 3. Rotate the illumination lamp socket counterclockwise to disengage it from the back of the switch housing. 4. Pull the knob off of the blower motor switch stem from the front of the accessory switch plate. 5. With a small thin-bladed screwdriver, gently pry the sides of the accessory switch plate to release the two snap clips on each side of the rear blower motor switch housing. 6. Remove the rear blower motor switch from the back of the accessory switch plate. INSTALLATION 1. Position the rear blower motor switch on the back of the accessory switch plate. 2. Firmly and evenly press the rear blower motor switch into the back of the accessory switch plate until it snaps into place. Be certain that all of the switch snap clip retainers are fully engaged. 3. Reinstall the knob onto the rear blower motor switch stem from the front of the accessory switch plate. Be certain to index the flat on the switch stem with the flat in the hub of the knob. 4. Reinstall the illumination lamp socket to the back of the rear blower motor switch housing. 5. Reinstall the accessory switch plate in the instrument panel. Refer to Accessory Switch Plate in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel procedures. 6. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation High Pressure Sensor / Switch: Description and Operation SYSTEM OPERATION High Pressure Cut-Off Switch The high pressure cut-off switch is located on the discharge line near the condenser. The switch is screwed onto a fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The discharge line fitting is equipped with an 0-ring to seal the switch connection. The high pressure cut-off switch is connected in series electrically with the low pressure cut-off switch between the fin sensing cycling clutch switch and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch on and off. This prevents compressor operation when the discharge line pressure approaches high levels. The high pressure cut-off switch contacts are open when the discharge line pressure rises above about 3100 to 3375 kPa (450 to 490 psi). The switch contacts will close when the discharge line pressure drops to about 1860 to 2275 kPa (270 to 330 psi). The high pressure cut-off switch is a factory-calibrated unit. The switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Page 5851 High Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the high pressure cut-off switch, verify that the refrigerant system has the correct refrigerant charge. See Refrigerant System Charge in the Service Procedures. 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the high pressure cut-off switch on the refrigerant system fitting. 3. Check for continuity between the two terminals of the high pressure cut-off switch. There should be continuity. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Page 5852 High Pressure Sensor / Switch: Service and Repair REMOVAL High Pressure Cut-Off Switch Removed/Install 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the high pressure cut-off switch, which is mounted to a fitting on the discharge line between the compressor and the condenser inlet. 3. Unscrew the high pressure cut-off switch from the discharge line fitting. 4. Remove the high pressure cut-off switch from the vehicle. 5. Remove the 0-ring seal from the discharge line fitting and discard. INSTALLATION 1. Lubricate a new 0-ring seal with clean refrigerant oil and install it on the discharge line fitting. Use only the specified 0-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the high pressure cut-off switch on the discharge line fitting. Tighten the switch to 7.5 N.m (5.5 ft. lbs.). 3. Plug the wire harness connector into the high pressure cut-off switch. 4. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams 8w-80-4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 5856 Low Pressure Sensor / Switch: Description and Operation SYSTEM OPERATION Fin Sensing Cycling Clutch Switch Fin Sensing Cycling Clutch Switch The fin sensing cycling clutch switch is used on this model to signal the Powertrain Control Module (PCM) to cycle the compressor clutch on arid off in order to control the evaporator temperature. Controlling the evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The fin sensing cycling clutch switch consists of a probe and a switch unit. The probe, which is a Negative Temperature Coefficient (NTC) thermistor in a capillary tube, is inserted between the front evaporator coil fins to monitor evaporator temperature. The switch unit contains internal control logic that monitors the input from the probe in order to switch an internal transistor that controls the output to the PCM. when the fin sensing cycling clutch switch sees a temperature input below about 1.60 °C (350 °F), it signals the PCM to cycle the compressor off. When the temperature input reaches above about 3.90 °C (390 °F), the switch signals the PCM to cycle the compressor back on. The fin sensing cycling clutch switch can be accessed for service by removing the screws and carefully lifting the front of the top cover up from the heater-A/C housing. The fin sensing cycling clutch switch is a sealed unit and cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Testing and Inspection > Fin Sensing Cycling Clutch Switch Low Pressure Sensor / Switch: Testing and Inspection Fin Sensing Cycling Clutch Switch Before testing the fin sensing cycling clutch switch, verity that the refrigerant system has the correct refrigerant charge. Also check that both the low and high pressure cut-off switches are functional, and confirm that the compressor clutch is operational. Use a volt/ohmmeter to test the switch. 1. Turn the ignition switch in the On position. Place the heater-A/C mode control switch in any A/C position. Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the fill sensing cycling clutch switch wire harness connector. If OK, go to Step 3. If not OK, repair the open circuit to the fuse in the junction block as required. 2. With the ambient temperature between 20 to 30° C (68 to 900 F), start the engine and run the air conditioning system. The compressor clutch should cycle on and off two to three times per minute. If the clutch fails to cycle at this rate in these temperatures, replace the faulty fin sensing cycling clutch switch. NOTE: If the ambient temperature is above 32° C (90° F) the compressor clutch may stay engaged and not cycle due to the high heat load. This condition is normal. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Testing and Inspection > Fin Sensing Cycling Clutch Switch > Page 5859 Low Pressure Sensor / Switch: Testing and Inspection Low Pressure Cut-Off Switch Before performing diagnosis of the low pressure cut-off switch, remember that lower ambient temperatures, below about -1° C (30° F), during cold weather will open the switch contacts and prevent compressor operation due to the pressure/temperature relationship of the refrigerant. Also verify that the refrigerant system has the correct refrigerant charge. See Refrigerant System Charge in the Service Procedures. 1. Disconnect and isolate the battery negative cable. 2. Unplug the low pressure cut-off switch wire harness connector from the switch on the suction line jumper fitting. 3. Install a jumper wire between the two cavities of the low pressure cut-off switch wire harness connector. 4. Connect a manifold gauge set to the refrigerant system service ports. See Refrigerant System Service Equipment and Refrigerant System Service Ports. 5. Connect the battery negative cable. 6. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 7. Check for continuity between the two terminals of the low pressure cut-off switch. There should be continuity with a suction pressure (low side) reading of 103 to 172 kPa (15 to 25 psi) or above, arid no continuity with a suction pressure reading of 48 to 90 kPa (7 to 13 psi) or below. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Fin Sensing Cycling Clutch Switch Replacement Low Pressure Sensor / Switch: Service and Repair Fin Sensing Cycling Clutch Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the screws that secure the top cover of the heater-A/C housing to the housing. 3. Unplug the wire harness connector from the fin sensing cycling clutch switch. Fin Sensing Cycling Clutch Switch Remove/Install 4. Carefully lift the front of the heater-A/C housing top cover far enough to access and remove the fin sensing cycling clutch switch probe from the evaporator coil fins. INSTALLATION 1. Carefully lift the heater-A/C housing top cover far enough to insert the fin sensing cycling clutch switch probe into the same hole between the evaporator coil fins from which it was removed. 2. Position the grommet on the fin sensing cycling clutch switch wire harness into the notch on the front edge of the lower heater-A/C housing. 3. Secure the top cover to the heater-A/C housing with the mounting screws. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 4. Plug in the fin sensing cycling clutch switch wire harness connector. 5. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Fin Sensing Cycling Clutch Switch Replacement > Page 5862 Low Pressure Sensor / Switch: Service and Repair Low Pressure Cut-Out Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Low Pressure Cut-Off Switch Remove/Install 2. Unplug the wire harness connector from the low pressure cut-off switch on the suction line jumper near the filter-drier. 3. Unscrew the low pressure cut-off switch from the fitting on the suction line jumper. 4. Remove the 0-ring seal from the suction line jumper fitting and discard. INSTALLATION 1. Lubricate a new 0-ring seal with clean refrigerant oil and install it on the suction line jumper fitting. Use only the specified 0-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the low pressure cut-off switch on the suction line jumper fitting. Tighten the switch to 4 N.m (2.9 ft. lbs.). 3. Plug the wire harness connector into the low pressure cut-off switch. 4. Connect the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation SYSTEM OPERATION The two refrigerant system service ports are used to charge, recover/recycle, evacuate, and test the air conditioning refrigerant system. Unique service port coupler sizes are used on the R-134a system, to ensure that the refrigerant system is not accidentally contaminated by the use of the wrong refrigerant (R-12), or refrigerant system service equipment. The high pressure service port is located on the discharge line between the compressor and the condenser, near the front of the engine compartment. The low pressure service port is located on the suction line jumper, near the filter-drier at the front of the engine compartment. Each of the service ports has a threaded plastic protective cap installed over it from the factory. After servicing the refrigerant system, always reinstall both of the service port caps. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Thermal Limiter Switch <--> [Thermal Limiting Fuse] > Component Information > Description and Operation Thermal Limiter Switch: Description and Operation SYSTEM OPERATION Thermal Limiter Switch The thermal limiter switch is used to measure the compressor surface temperature. If the compressor surface temperature is excessive, the switch will cut the battery feed voltage to the compressor clutch coil. The switch will reset itself, once the compressor surface temperature returns to normal. The thermal limiter switch will interrupt the battery feed to the compressor clutch coil at a temperature of about 122 to 128° C (250 to 260° F). The switch will reset and restore the clutch coil operation at a temperature of about 104 to 116° C (220 to 240° F). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Thermal Limiter Switch <--> [Thermal Limiting Fuse] > Component Information > Description and Operation > Page 5869 Thermal Limiter Switch: Testing and Inspection The thermal limiter switch is calibrated to open and close as follows: _ Open circuit (no continuity) at 125° C ± 3° C (255° F ± 5° F) _ Closed circuit (continuity) at 110° C ± 6° C (230° F ± 10° F). 1. Unplug the wire harness connectors from the thermal limiter switch. 2. Use an ohmmeter to check for correct continuity, as indicated above, between the two thermal limiter switch terminals. if the continuity is incorrect, replace the faulty switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Thermal Limiter Switch <--> [Thermal Limiting Fuse] > Component Information > Description and Operation > Page 5870 Thermal Limiter Switch: Service and Repair After removing the thermal limiter switch, always replace it with a new unit. The refrigerant system can remain fully-charged during thermal limiter switch replacement. REMOVAL 1. Unplug the two wire harness connectors between the compressor clutch wire harness and the thermal limiter switch. Thermal Limiter Switch Remove/Install 2. Remove the single screw that secures the thermal limiter switch clamp to the top of the compressor housing. 3. Using a straight-bladed screwdriver, pry the thermal switch from the socket in the top of the compressor housing. 4. Remove the thermal limiter switch from the compressor. Cleaning 1. Remove the old silicone sealant filler from the thermal limiter switch socket on the top of the compressor housing. 2. Thoroughly clean the thermal limiter switch socket with paint thinner or another suitable solvent that leaves no residue. INSTALLATION 1. Place the new thermal limiter switch on a suitable work bench with the flat copper surface of the switch facing upward. 2. Apply an even coating of RTV silicone sealant to the flat copper surface of the thermal limiter switch. Dispense and apply the silicone sealant to the switch directly from the tube, and do not try to spread the material with your fingers. 3. Install the thermal limiter switch with the flat copper surface facing downward into the socket of the compressor housing. 4. Position the clamp over the thermal limiter switch and secure the clamp to the compressor housing with the mounting screw. Tighten the mounting screw to 1.8 N.m (17 in. lbs.). 5. Plug in the thermal limiter switch wire harness connectors to the compressor clutch wire harness. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Description and Operation Vacuum Check Valve HVAC: Description and Operation SYSTEM OPERATION A vacuum check valve is installed in the vacuum supply line in the vacuum harness. The check valve is located near the left end of the distribution duct under the instrument panel in the passenger compartment. The vacuum check valve is designed to allow vacuum to flow in only one direction through the vacuum supply circuits. The use of a vacuum check valve helps to maintain the system vacuum needed to retain the selected heater-A/C mode settings. The check valve will prevent the engine from bleeding down system vacuum through the intake manifold during extended heavy engine load (low engine vacuum) operation. The vacuum check valve cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Description and Operation > Page 5874 Vacuum Check Valve HVAC: Testing and Inspection Adjust Vacuum Test Bleed Valve Vacuum control is used to operate the mode doors in the heater-only and the heater-A/C systems. Testing of the heater-A/C mode control switch operation will determine if the vacuum and electrical controls are functioning. However, it is possible that a vacuum control system that operates perfectly at engine idle (high engine vacuum) may not function properly at high engine speeds or loads (low engine vacuum). This can be caused by leaks in the vacuum system, or by a faulty or improperly installed vacuum check valve. A vacuum system test will help to identify the source of poor vacuum system performance or vacuum system leaks. Before starting this test, stop the engine and make certain that the problem is not a disconnected vacuum supply tube at the engine vacuum source or at the vacuum reservoir. Use an adjustable vacuum test set (Special Tool C-3707) and a suitable vacuum pump to test the heater-A/C vacuum control system. With a finger placed over the end of the vacuum test hose probe, adjust the bleed valve on the test set gauge to obtain a vacuum of exactly 27 kPa (8 in. Hg.). Release and block the end of the probe several times to verify that the vacuum reading returns to the exact 27 kPa (8 in. Hg.) setting. Otherwise, a false reading will be obtained during testing. Vacuum Check Valve 1. Remove the vacuum check valve. The valve is located in the vacuum supply tube (black) within the vacuum harness on the left end of the distribution duct under the instrument panel in the passenger compartment. The vacuum check valve must be removed in order to perform the following tests. See Vacuum Check Valve in the Removal and Installation procedures. 2. Connect the test set vacuum supply hose to the heater-A/C control side of the valve. When connected to this side of the check valve, no vacuum should pass and the test set gauge should return to the 27 kPa (8 in. Hg.) setting. If OK, go to step Step 4. If not OK, replace the faulty valve. 3. Connect the test set vacuum supply hose to the engine vacuum side of the valve. When connected to this side of the check valve, vacuum should flow through the valve without restriction. If not OK, replace the faulty valve. Heater-A/C Controls 1. Connect the test set vacuum probe to the heater-A/C vacuum supply (black) tube in the engine compartment. Position the test set gauge so that it can be viewed from the passenger compartment. 2. Place the heater-A/C mode control switch knob in each mode position, one position at a time, and pause after each selection. The test set gauge should return to the 27 kPa (8 in. Hg.) setting shortly after each selection is made. If not OK, a component or vacuum line in the vacuum circuit of the selected mode has a leak. See Locating Vacuum Leaks. CAUTION: Do not use lubricant on the switch ports or in the holes in the plug, as lubricant will ruin the vacuum valve in the switch. A drop of clean water in the connector plug holes will help the connector slide onto the switch ports. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Description and Operation > Page 5875 Vacuum Circuit Test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Description and Operation > Page 5876 Vacuum Circuits Locating Vacuum Leaks WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect the vacuum harness connector on the back of the heater-A/C mode control switch on the instrument panel. 2. Connect the test set vacuum hose probe to each p0rt in the vacuum harness connector, one port at a time, and pause after each connection. The test set gauge should return to the 27 kPa (8 in. Hg.) setting shortly after each connection is made. if OK, replace the faulty heater-A/C control. if not OK, go to Step 4. 3. Determine the vacuum line color of the vacuum circuit that is leaking. To determine the vacuum line colors, see the Vacuum Circuits chart. 4. Disconnect and plug the vacuum line from the component (fitting, actuator, valve, switch, or reservoir) on the other end of the leaking circuit. instrument panel disassembly or removal may be necessary to gain access to some components. 5. Connect the test set hose or probe to the open end of the leaking circuit. The test set gauge should return to the 27 kPa (8 in. Hg.) setting shortly Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Description and Operation > Page 5877 after each connection is made. If OK, replace the faulty disconnected component. If not OK, go to Step 7. 6. To locate a leak in a vacuum line, leave one end of the line plugged and connect the test set hose or probe to the other end of the line. Run your fingers slowly along the line while watching the test set gauge. The vacuum reading will fluctuate when your fingers contact the source of the leak. To repair the vacuum line, cut out the leaking section of the line. Then, insert the loose ends of the line into a suitable length of 3 millimeter (0.125 inch) inside diameter rubber hose. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Description and Operation > Page 5878 Vacuum Check Valve HVAC: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Remove the engine cover from the passenger compartment. Vacuum Check Valve 2. Look between the upper dash panel engine housing extension and the bottom of the instrument panel to locate the vacuum check valve, which is installed in the housing half of the vacuum harness which is secured near the left defroster outlet on the distribution duct. 3. Note the orientation of the check valve in the vacuum supply line for correct reinstallation. 4. Unplug the vacuum check valve from the connectors in the vacuum harness. 5. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Description and Operation Vacuum Reservoir HVAC: Description and Operation SYSTEM OPERATION The vacuum reservoir is mounted in the engine compartment on the right cowl side panel near the speed control servo and below the right headlamp. The right front fender extension panel must be removed from the vehicle to access the vacuum reservoir for service. Engine vacuum is stored in the vacuum reservoir. The stored vacuum is used to operate the vacuum-controlled vehicle accessories during periods of low engine vacuum such as when the vehicle is climbing a steep grade, or under other high engine load operating conditions. The vacuum reservoir cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Description and Operation > Page 5882 Vacuum Reservoir HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the right front fender extension from the fender. Vacuum Reservoir Remove/Install 3. Unplug the vacuum harness connector from the vacuum reservoir. 4. Remove the two screws that secure the vacuum reservoir to the right cowl side panel. 5. Remove the vacuum reservoir from the right cowl side panel. 6. Reverse the removal procedures to install. Tighten the mounting screws to 3.9 N.m (35 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: The airbag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the airbag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the airbag and possible personal injury. The fasteners, screws, and bolts, originally used for the airbag components, have special coatings and are specifically designed for the airbag system. They must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books . Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 5888 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service Air Bag: Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 5893 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 5894 Air Bag: Diagrams Driver Squib Connector Passenger Squib Connector Passenger Squib Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 5895 Air Bag: Description and Operation SYSTEM OPERATION Airbag Module Driver Side The airbag module protective trim cover is the most visible part of the driver side airbag system. The module is mounted directly to the steering wheel. Located under the airbag module trim cover are the horn switch, the airbag cushion, and the air-bag cushion supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. Upon airbag deployment, this cover will split at a predetermined breakout line. Passenger Side The airbag door on the instrument panel above the glove box is the most visible part of the passenger side airbag system. Located under the airbag door are the airbag cushion and its supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator includes a small canister of highly compressed argon gas. The inflator seals the hole in the airbag cushion so it can discharge the compressed gas it contains directly into the cushion when supplied with the proper electrical signal. The airbag door is secured to the airbag module and the instrument panel base trim, and has predetermined breakout lines concealed beneath its decorative cover. Upon airbag deployment, the airbag door will split at the breakout lines and the door will pivot out of the way. The airbag module is secured with screws at the rear to the instrument panel glove box opening reinforcement, and at the front it is secured to a bracket on the instrument panel armature. The airbag module and airbag door are available as separate service items. Following an airbag deployment, the airbag module and airbag door must be replaced. Storage An airbag module must be stored in its original, special container until used for service. Also, it must be stored in a clean, dry environment; away from sources of extreme heat, sparks, and high electrical energy. Always place or store an airbag module on a surface with its trim cover or airbag side facing up, to minimize movement in case of an accidental deployment. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Replacement Air Bag: Service and Repair Air Bag Replacement WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - WHEN REMOVING A DEPLOYED AIRBAG MODULE, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG MODULE AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. Driver Side 1. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. Driver Side Airbag Module Remove/Install 2. From the underside of the steering wheel, remove the two screws that secure the driver side airbag module to the steering wheel. 3. Pull the airbag module away from the steering wheel far enough to access the wire harness connectors on the back of the airbag module. 4. Unplug the airbag module and horn switch wire harness connectors from the back of the airbag module. 5. Remove the driver side airbag module from the steering wheel. 6. If the airbag has been deployed, the clockspring must be replaced and the steering column must be inspected. See Clockspring service procedures. 7. When installing the airbag module, connect the clockspring wire harness connector to the module by pressing straight in on the connector. Be certain that the connector is fully engaged by observing the latch arms on each side of the connector. When these arms move outward from the connector, the connector is latched. 8. Connect the horn switch wire harness connector. 9. Position the airbag module in the steering wheel. Be certain that the airbag and horn wiring is not pinched between the airbag module and the steering wheel armature. 10. Install the airbag module mounting screws. Tighten the mounting screws to 10.2 N.m (90 in. lbs.). 11. Do not connect the battery negative cable at this time. See Airbag System in the Diagnosis and Testing procedures. Passenger Side 1. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Roll down the glove box from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Glove Box -Roll Down Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Replacement > Page 5898 Passenger Side Airbag Remove/Install 3. Remove the three small screws and Three small screws that secure the passenger side airbag module rear bracket and airbag door lower flange to the glove box opening upper reinforcement. 4. Reach through and above the glove box opening to access and unplug the passenger side airbag module wire harness connector located on the instrument panel armature. 5. Reach through and above the glove box opening to remove the two screws that secure the passenger side airbag module front bracket to the instrument panel armature. 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper edge of the passenger side airbag door away from the instrument panel to release the five snap retainers. 7. Remove the passenger side airbag module and door from the instrument panel as a unit. 8. Reverse the removal procedures to install. When reinstalling the airbag door to the instrument panel top cover, be certain that the snap retainers on the upper edge of the airbag door are fully engaged in the five instrument panel receptacles. Tighten the three small screws for the passenger side airbag door lower flange on the glove box opening upper reinforcement to 1.9 N.m (17 in. lbs.). Tighten the four passenger side airbag module front and rear bracket mounting screws to 8.4 N.m (75 in. lbs.). 9. Before reinstalling the glove box, be certain that the airbag module wire harness connector latches are fully engaged. 10. Do not connect the battery negative cable at this time. See Airbag System in the Diagnosis and Testing procedures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Replacement > Page 5899 Air Bag: Service and Repair Driver Side Airbag Module Trim Cover Replacement REMOVAL WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE HORN SWITCH IS INTEGRAL TO THE AIRBAG MODULE TRIM COVER. SERVICE OF THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the driver side airbag module from the steering wheel. See Airbag Module -Driver Side in the Replacement. Airbag Trim Cover Retainer Nuts Remove/Install 3. Remove the four nuts that secure the upper and lower trim cover retainers to the studs on the airbag housing. Airbag Trim Cover Retainers Remove/Install 4. Remove the upper and lower trim cover retainers from the airbag housing studs. 5. Remove the horn switch ground wire eyelet from the airbag housing stud. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Replacement > Page 5900 Airbag Trim Cover Remove/Install 6. Disengage the six trim cover locking blocks from the lip around the outside edge of the airbag housing and remove the housing from the cover. WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE DRIVER SIDE AIRBAG MODULE TRIM COVER AND THE DRIVER SIDE AIRBAG MODULE. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. 7. When installing the trim cover and horn switch, be certain that the locking blocks are fully engaged on the lip of the airbag housing. Driver Side Airbag Trim Cover Locking Blocks Engaged 8. When installing the upper and lower trim cover retainers, be certain that the tabs on each retainer are engaged in the retainer slots of the trim cover. 9. Install and tighten the trim cover retainer nuts to 10 N.m (90 in. lbs.). 10. Reverse the remaining removal procedures to complete the installation, but do not connect the battery negative cable at this time. See Airbag System in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Replacement > Page 5901 Air Bag: Service and Repair Passenger Side Airbag Door Replacement REMOVAL AND INSTALLATION WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - WHEN REMOVING A DEPLOYED AIRBAG MODULE, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG MODULE AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. 1. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the passenger side airbag module from the instrument panel. See Air Bag System/Airbag Module -Passenger Side Replacement. Passenger Side Airbag Door Remove/Install 3. With the airbag module on a bench, remove the two screws that secure one of the end brackets to the passenger side airbag module and remove the bracket. 4. Slide the passenger side airbag door sideways towards the end of the airbag module from which the bracket was removed until the upper and lower airbag door flanges clear the slots on the top and the bottom of the airbag housing. 5. Remove the passenger side airbag door from the airbag module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module Technical Service Bulletin # 816 Date: 990201 Recall - Airbag Electronic Control Module February 1999 Safety Recall No. 816 Airbag Electronic Control Module Models 1998 (AB) Dodge Ram Vans and Wagons NOTE: This recall applies only to vehicles built through June 5, 1998 (MDH 060517). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using the DIAL VIP System. Subject If an object impacts the airbag electronic control module (AECM) on about 46,000 of the above vehicles, the module may inadvertently deploy both airbags. Inadvertent airbag deployment can injure a front seat occupant. Repair The AECM must be replaced and a protective cover must be installed over the new AECM. Part Number Description CCF18160 AECM Package Each package contains the following components: Quantity Description 1 AECM 1 AECM Cover 3 Screws - AECM-to-Floor Pan Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough AECM Packages to service about 25% of those vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced, must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace AECM and install cover 08816182 0.4 hours Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing instructions Parts Return Not required. Dealer Notification & Vehicle List Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module > Page 5910 All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the CMMS and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD816". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed, Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive Last Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Using a trim panel removal tool, remove the push-in fasteners that attach the seat riser trim shield to the rear of the driver's seat riser (if equipped) (Figure 1). Set the trim shield aside. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module > Page 5911 3. Remove the power seat wiring harness connector from the front riser crossmember and then disconnect the connector (if equipped) (Figure 2). 4. Remove the nuts that attach the driver's seat riser to the floor pan (Figure 2). 5. Remove the driver's seat assembly from the vehicle. 6. Disconnect the airbag electronic control module (AECM) wiring connector. 7. Remove the three (3) screws that attach the AECM to the floor pan mounting bracket (Figure 3). Discard the screws. 8. Remove the AECM. Destroy the old AECM connector pins and then discard the old AECM. 9. Install the supplied AECM. Position the AECM on the floor pan mounting bracket with the arrow on the housing pointing forward (Figure 3). 10. Install the three provided AECM mounting screws. Tighten the screws to 105 in-lbs (11.8 N.m). 11. Connect the AECM wiring connector. Make sure that the connector latches are fully engaged. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module > Page 5912 12. Clean the floor pan area around the AECM. 13. Remove the "peel and stick" backing paper from the adhesive strips on the provided AECM cover. 14. Install the cover over the AECM. Press down firmly to ensure that the adhesive strips are securely attached to the floor pan (Figure 4). Note: Position the cover so that the vehicle wiring harnesses are routed through the cover openings. Ensure that the power seat wiring harness is not trapped under the cover. 15. Install the driver's seat assembly into the vehicle. 16. Install the nuts that attach the driver's seat riser to the floor (Figure 2). Tighten the nuts to 55 ft-lbs (75 N.m). 17. Connect the power driver seat wiring harness connector and attach it to the front riser crossmember (if equipped) (Figure 2). 18. Attach the riser trim shield to the rear of the driver's seat riser with the push-in fasteners (if equipped) (Figure 1). 19. Turn the ignition switch to the "RUN" position. 20. Connect the negative battery cable. 21. From outside the vehicle, turn the ignition switch to the "OFF" position for about 10 seconds and then turn it back to the "RUN" position. 22. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light, or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG ELECTRONIC CONTROL MODULE Dear Ram Van or Wagon Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. DaimlerChrysler Corporation has determined that a defect, which relates to motor vehicle safety, exists in some 1998 Dodge Ram Vans and Wagons. The problem is... If an object impacts the airbag electronic control module (AECM) under the driver's seat of your Ram van or wagon (identified on the enclosed form), the module may inadvertently deploy both airbags. Inadvertent airbag deployment can injure a front seat occupant. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module > Page 5913 What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the AECM and install a protective cover over it. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, DC 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. Washington, DC area residents may call 1-202-366-0123. We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. 816 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module Technical Service Bulletin # 816 Date: 990201 Recall - Airbag Electronic Control Module February 1999 Safety Recall No. 816 Airbag Electronic Control Module Models 1998 (AB) Dodge Ram Vans and Wagons NOTE: This recall applies only to vehicles built through June 5, 1998 (MDH 060517). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using the DIAL VIP System. Subject If an object impacts the airbag electronic control module (AECM) on about 46,000 of the above vehicles, the module may inadvertently deploy both airbags. Inadvertent airbag deployment can injure a front seat occupant. Repair The AECM must be replaced and a protective cover must be installed over the new AECM. Part Number Description CCF18160 AECM Package Each package contains the following components: Quantity Description 1 AECM 1 AECM Cover 3 Screws - AECM-to-Floor Pan Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough AECM Packages to service about 25% of those vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced, must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace AECM and install cover 08816182 0.4 hours Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing instructions Parts Return Not required. Dealer Notification & Vehicle List Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module > Page 5919 All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the CMMS and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD816". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed, Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive Last Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Using a trim panel removal tool, remove the push-in fasteners that attach the seat riser trim shield to the rear of the driver's seat riser (if equipped) (Figure 1). Set the trim shield aside. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module > Page 5920 3. Remove the power seat wiring harness connector from the front riser crossmember and then disconnect the connector (if equipped) (Figure 2). 4. Remove the nuts that attach the driver's seat riser to the floor pan (Figure 2). 5. Remove the driver's seat assembly from the vehicle. 6. Disconnect the airbag electronic control module (AECM) wiring connector. 7. Remove the three (3) screws that attach the AECM to the floor pan mounting bracket (Figure 3). Discard the screws. 8. Remove the AECM. Destroy the old AECM connector pins and then discard the old AECM. 9. Install the supplied AECM. Position the AECM on the floor pan mounting bracket with the arrow on the housing pointing forward (Figure 3). 10. Install the three provided AECM mounting screws. Tighten the screws to 105 in-lbs (11.8 N.m). 11. Connect the AECM wiring connector. Make sure that the connector latches are fully engaged. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module > Page 5921 12. Clean the floor pan area around the AECM. 13. Remove the "peel and stick" backing paper from the adhesive strips on the provided AECM cover. 14. Install the cover over the AECM. Press down firmly to ensure that the adhesive strips are securely attached to the floor pan (Figure 4). Note: Position the cover so that the vehicle wiring harnesses are routed through the cover openings. Ensure that the power seat wiring harness is not trapped under the cover. 15. Install the driver's seat assembly into the vehicle. 16. Install the nuts that attach the driver's seat riser to the floor (Figure 2). Tighten the nuts to 55 ft-lbs (75 N.m). 17. Connect the power driver seat wiring harness connector and attach it to the front riser crossmember (if equipped) (Figure 2). 18. Attach the riser trim shield to the rear of the driver's seat riser with the push-in fasteners (if equipped) (Figure 1). 19. Turn the ignition switch to the "RUN" position. 20. Connect the negative battery cable. 21. From outside the vehicle, turn the ignition switch to the "OFF" position for about 10 seconds and then turn it back to the "RUN" position. 22. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light, or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG ELECTRONIC CONTROL MODULE Dear Ram Van or Wagon Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. DaimlerChrysler Corporation has determined that a defect, which relates to motor vehicle safety, exists in some 1998 Dodge Ram Vans and Wagons. The problem is... If an object impacts the airbag electronic control module (AECM) under the driver's seat of your Ram van or wagon (identified on the enclosed form), the module may inadvertently deploy both airbags. Inadvertent airbag deployment can injure a front seat occupant. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module > Page 5922 What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the AECM and install a protective cover over it. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, DC 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. Washington, DC area residents may call 1-202-366-0123. We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. 816 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5923 Air Bag Control Module: Locations Module Locations Air Bag Control Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5924 Air Bag Control Module: Diagrams ACM Connector ACM Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5925 Air Bag Control Module: Description and Operation SYSTEM OPERATION The Airbag Control Module (ACM) is secured to a bracket on the floor panel underneath the driver side front seat in the passenger compartment of the vehicle. The ACM contains a microprocessor that contains the airbag system logic, the impact sensor, and an energy storage capacitor. The ACM system logic includes On-Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry on the Chrysler Collision Detection (CCD) data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the CCD data bus to turn on the airbag indicator lamp. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate signaled by the impact sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the air-bag system components. Only one impact sensor is used in this airbag system. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5926 Air Bag Control Module: Service and Repair REMOVAL AND INSTALLATION WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - NEVER STRIKE OR KICK THE AIR BAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. ALWAYS REINSTALL THE AIRBAG CONTROL MODULE PROTECTIVE COVER. 1. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Reach under the driver side front seat to access and unplug the wire harness connector from the Air-Bag Control Module (ACM). Airbag Control Module Remove/Install 3. Remove the three screws that secure the ACM to the mounting bracket on the floor panel under the driver seat. 4. Remove the ACM from the floor panel mounting bracket. 5. When installing the ACM, position the unit with the arrow on the ACM housing pointing forward. 6. Secure the ACM to the floor panel mounting bracket with the three mounting screws. Tighten the mounting screws to 11.8 N.m (105 in. lbs.). 7. Plug in the wire harness connector to the ACM. Be certain that the connector latches are fully engaged. 8. Do not connect the battery negative cable at this time. See Airbag System in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5931 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5932 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5933 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5935 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5936 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5937 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5938 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5939 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5940 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5941 PARTS REQUIRED: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5942 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5943 POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations Passenger Airbag Switch Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations > Page 5946 Passenger Side Airbag On/Off Switch Remove/Install Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 5947 Air Bag Deactivation Switch: Diagrams Passenger Airbag Switch Connector Passenger Airbag Switch Connector Passenger Airbag Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 5948 Air Bag Deactivation Switch: Service and Repair REMOVAL WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the accessory switch plate from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Accessory Switch Plate Replacement. Passenger Side Airbag On/Off Switch Remove/Install 3. Remove the two screws that secure the passenger airbag disarm switch to the back of the accessory switch plate. 4. Remove the passenger airbag disarm switch from the accessory switch plate. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 6. Do not connect the battery negative cable at this time. See Airbag System in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service Clockspring Assembly / Spiral Cable: Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 5953 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5954 Clockspring Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5955 Clockspring Assembly / Spiral Cable: Description and Operation SYSTEM OPERATION The clockspring is used to maintain a continuous electrical circuit between the instrument panel wire harness, the driver side airbag module, and the vehicle speed control switches on vehicles that are so equipped. The clockspring is mounted on the steering column behind the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring must be properly centered when it is installed on the steering column following any service removal, or it will be damaged. See Clockspring Centering in the Adjustments for the procedures. The clockspring cannot be repaired. If the clock-spring is faulty, damaged, or if the airbag has been deployed, the clockspring must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5956 Clockspring Assembly / Spiral Cable: Adjustments The clockspring is designed to wind and unwind when the steering wheel is rotated, but is only designed to rotate the same number of turns (about five complete rotations) as the steering wheel can be turned from stop to stop. If the rotating tape within the clockspring is not indexed properly to the steering wheel and the front wheels, the clockspring may become wound too tight and fail during use. The clockspring must be centered if it is not known to be properly indexed, or if the front wheels were moved from the straight-ahead position with the clockspring removed during any service procedure. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Turn the steering wheel until the front wheels are in the straight-ahead position before starting the centering procedure. 2. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 3. Remove the clockspring from the steering column. See Clockspring Replacement. Clockspring Centering 4. Hold the clockspring with the bottom side facing up and depress the spring lock. 5. Keeping the spring lock depressed, rotate the clockspring hub counterclockwise to the end of its travel. Do not apply excessive torque. 6. From the end of the counterclockwise travel, rotate the clockspring hub about two and one-half turns clockwise, then release the spring lock between the locking tabs. 7. The front wheels should still be in the straight ahead position. Reinstall the clockspring on the steering column. See Clockspring Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5957 Clockspring Assembly / Spiral Cable: Service and Repair WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Turn the steering wheel until the front wheels are in the straight-ahead position before starting the procedure. 2. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 3. Remove the driver side airbag module from the steering wheel. See Airbag Module Replacement for the procedures. 4. If the vehicle is equipped with the optional vehicle speed control, unplug the wire harness connectors from the speed control switches in the steering wheel. 5. Remove the nut that secures the steering wheel to the steering column upper shaft. 6. Remove the steering wheel with a steering wheel puller (Special Tool C-3428-B). 7. Remove the knee blocker from the instrument panel. Refer Instrument Panel, Gauges and Warning Indicators/Instrument Panel to Knee Blocker 8. If the vehicle is so equipped, remove the tilt steering column lever by grasping the lever firmly and pulling it sharply away from the column. Lower Steering Column Shroud Screws 9. Remove the two screws from the bottom of the lower steering column shroud that secure it to the upper shroud. 10. Unsnap the front and both sides of the lower shroud from the upper shroud. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5958 Lower Steering Column Shroud Remove/Install 11. Tilt the lower shroud downward and slide it back to disengage the hooks from the pivots on the upper shroud. Upper Steering Column Shroud Remove/Install 12. Remove the two screws that secure the upper shroud to the steering column. 13. Remove the upper shroud from the steering column. Steering Column Tie-Wraps 14. Remove the two upper wire harness tie wraps, but not the clockspring wire harness tie wrap or the overdrive switch wire harness tie wrap. 15. Unplug the wire harness connector between the clockspring and the instrument panel wire harness, located on the left side of the steering column wire harness connector mounting bracket. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5959 Clockspring Remove/Install 16. Using snap ring pliers, remove the snap ring that secures the clockspring to the upper steering column shaft. 17. To remove the clockspring, carefully lift the locating fingers of the clockspring assembly from the steering column as necessary. The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the airbag has been deployed. INSTALLATION 1. Before reinstalling the clockspring on the steering column, be certain that the wave washer is in place on the upper steering column shaft. CAUTION: Before reinstalling the clockspring, be certain that the front wheels are still in the straight-ahead position, the alignment spline on the upper steering column shaft is in the 12 o'clock position, and that the clockspring is centered. See Clockspring Centering in the Adjustments for the centering procedure. Failure to follow these procedures may result in damage to the clockspring. 2. Align the hole in the clockspring hub with the horn tower and slide the clockspring onto the upper steering column shaft. 3. Reinstall the snap ring onto the upper steering column shaft. Be certain that the snap ring is fully seated in the groove on the shaft. NOTE: The clockspring wire harness tie-wrap must be positioned above the upper steering column wire harness tie-wrap. 4. Route the clockspring wire harness along the steering column wire harness and secure the harnesses with two new tie-wraps. Be certain that the new tie-wraps are installed in the same positions as those that were removed and that the steering column wire harnesses are routed so that they will not be pinched or stretched. 5. Plug the clockspring wire harness connector into the instrument panel wire harness connector. Be certain that the connector latches are fully engaged. NOTE: Before reinstalling the upper shroud on the steering column, be certain that the upper shroud spacer mounting stud is fully seated to the mounting boss on the inside surface of the shroud. 6. Reinstall the steering column shrouds. Be certain that the upper shroud spacer mounting stud is fully seated to the mounting boss on the inside of the shroud. Tighten the upper shroud mounting screws to 1.4 N.m (12 in. lbs.). Tighten the lower shroud mounting screws to 3.4 N.m (30 in. lbs.). 7. Reinstall the steering column opening cover and the knee blocker to the instrument panel. Refer to Steering and Suspension/Steering/Steering Column Opening Cover and to Knee Blocker. 8. Install the steering wheel being certain to index the alignment splines in the hub of the steering wheel with the splines on the upper steering column shaft. Pull the wire harnesses from the clockspring between the steering wheel back trim cover and the steering wheel armature. Tighten the steering wheel nut to 61 N.m (45 ft. lbs.). Be certain not to pinch the wiring between the steering wheel and the nut. 9. If the vehicle is so equipped, plug in the wire harness connectors to the vehicle speed control switches. 10. Install the driver side airbag module onto the steering wheel. See Airbag Module Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation Malfunction Lamp / Indicator: Description and Operation SYSTEM OPERATION The airbag indicator lamp gives an indication when the airbag system is faulty or inoperative. The lamp is controlled by the instrument cluster circuitry based upon messages received from the Airbag Control Module (ACM) on the Chrysler Collision Detection (CCD) data bus. The lamp is turned on by the ACM for about seven seconds when the ignition switch is turned to the On position as a bulb test. The ACM continually monitors the airbag system circuits and sensors to decide whether the system is in good operating condition. The ACM then sends the proper messages to the instrument cluster on the CCD data bus to turn the lamp on or off. If the ACM turns the lamp on after the bulb test, it indicates the ACM has detected a system malfunction and/or that the airbag system has become inoperative. The instrument cluster circuitry will also send a chime request to the Central Timer Module (CTM) when a lamp-on message is received from the ACM. A lamp-on message does not mean that either or both airbags will not deploy upon an impact, only that they might not deploy, depending upon the nature of the detected malfunction. Each time that the instrument cluster circuitry receives a lamp-on message from the ACM, it will light the lamp for three seconds or the duration of the airbag system malfunction, whichever is longer. The airbag indicator lamp also has a lamp backup feature. About ten seconds after the ignition switch is turned to the On position, if an inoperative airbag warning lamp circuit was detected during the bulb test sequence, the instrument cluster circuitry will flash the seat belt reminder lamp on and off for about thirty seconds. If the seat belt reminder lamp stays on after flashing for thirty seconds, or comes on at any time other than about ten seconds after the initial ignition-on sequence, it may indicate that an airbag system fault has been detected and that the airbag indicator lamp is inoperative. See Seat Belt Reminder Lamp in the Description and Operation for more information on the airbag lamp backup feature. Refer to Air Bag Systems for more information on airbags. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation > Page 5963 Malfunction Lamp / Indicator: Testing and Inspection The diagnosis found here addresses an inoperative airbag indicator lamp condition. If the airbag indicator lamp stays on with the ignition switch in the On position, or comes on and stays on while driving, refer to Air Bag Systems for diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The airbag indicator lamp has a lamp backup feature. Ten seconds after the ignition switch is turned to the On position, if the instrument cluster circuitry has detected an inoperative airbag warning lamp circuit it will flash the seat belt reminder lamp on and off for thirty seconds. Once the instrument cluster circuitry has detected an inoperative airbag warning lamp circuit, if a lamp-on message is received from the Airbag Control Module (ACM) on the Chrysler Collision Detection (CCD) data bus, the seat belt reminder lamp will remain on for the duration of the airbag system malfunction. If the airbag indicator lamp fails to light when the ignition switch is turned to the On position, and the seat belt reminder lamp flashes following its normal display function (about six seconds after the ignition switch is turned to the On position), diagnosis of the airbag system and/or the CCD data bus should be performed with a DRB scan tool as described in the proper Diagnostic Procedures. For further diagnosis of the airbag indicator lamp and the instrument cluster circuitry, see Instrument Cluster in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5968 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5969 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5970 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5971 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5972 TIME ALLOWANCE: FAILURE CODE: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair Knee Diverter: Service and Repair Knee Blocker REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover. See Steering Column Opening Cover Replacement. 3. Remove the two screws that secure the park brake release handle to the lower edge of the knee blocker and lower the handle to the floor. 4. Remove the two screws that secure the 16-way data link connector to the lower edge of the knee blocker and lower the connector to the floor. 5. Remove the two screws that secure the inside hood release handle to the lower edge of the knee blocker and lower the handle to the floor. Steering Column Support Bracket 6. Reach under the instrument panel to loosen the two screws that secure the slotted holes of the knee blocker to the steering column support bracket. Knee Blocker Remove/Install 7. Remove the four screws that secure the knee blocker to the instrument panel on each side of the steering column opening. 8. Pull the knee blocker rearward far enough for the slotted holes to clear the loosened screws on the steering column support bracket. 9. Remove the knee blocker from the instrument panel. 10. Reverse the removal procedures to install. Tighten the mounting hardware as follows: - Knee blocker to instrument panel screws - 1.9 N.m (17 in. lbs.) - Knee blocker to steering column support bracket screws - 28 N.m (250 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 816 > Feb > 99 > Recall Airbag Electronic Control Module Technical Service Bulletin # 816 Date: 990201 Recall - Airbag Electronic Control Module February 1999 Safety Recall No. 816 Airbag Electronic Control Module Models 1998 (AB) Dodge Ram Vans and Wagons NOTE: This recall applies only to vehicles built through June 5, 1998 (MDH 060517). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using the DIAL VIP System. Subject If an object impacts the airbag electronic control module (AECM) on about 46,000 of the above vehicles, the module may inadvertently deploy both airbags. Inadvertent airbag deployment can injure a front seat occupant. Repair The AECM must be replaced and a protective cover must be installed over the new AECM. Part Number Description CCF18160 AECM Package Each package contains the following components: Quantity Description 1 AECM 1 AECM Cover 3 Screws - AECM-to-Floor Pan Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough AECM Packages to service about 25% of those vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced, must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace AECM and install cover 08816182 0.4 hours Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing instructions Parts Return Not required. Dealer Notification & Vehicle List Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 816 > Feb > 99 > Recall Airbag Electronic Control Module > Page 5985 All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the CMMS and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD816". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed, Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive Last Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Using a trim panel removal tool, remove the push-in fasteners that attach the seat riser trim shield to the rear of the driver's seat riser (if equipped) (Figure 1). Set the trim shield aside. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 816 > Feb > 99 > Recall Airbag Electronic Control Module > Page 5986 3. Remove the power seat wiring harness connector from the front riser crossmember and then disconnect the connector (if equipped) (Figure 2). 4. Remove the nuts that attach the driver's seat riser to the floor pan (Figure 2). 5. Remove the driver's seat assembly from the vehicle. 6. Disconnect the airbag electronic control module (AECM) wiring connector. 7. Remove the three (3) screws that attach the AECM to the floor pan mounting bracket (Figure 3). Discard the screws. 8. Remove the AECM. Destroy the old AECM connector pins and then discard the old AECM. 9. Install the supplied AECM. Position the AECM on the floor pan mounting bracket with the arrow on the housing pointing forward (Figure 3). 10. Install the three provided AECM mounting screws. Tighten the screws to 105 in-lbs (11.8 N.m). 11. Connect the AECM wiring connector. Make sure that the connector latches are fully engaged. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 816 > Feb > 99 > Recall Airbag Electronic Control Module > Page 5987 12. Clean the floor pan area around the AECM. 13. Remove the "peel and stick" backing paper from the adhesive strips on the provided AECM cover. 14. Install the cover over the AECM. Press down firmly to ensure that the adhesive strips are securely attached to the floor pan (Figure 4). Note: Position the cover so that the vehicle wiring harnesses are routed through the cover openings. Ensure that the power seat wiring harness is not trapped under the cover. 15. Install the driver's seat assembly into the vehicle. 16. Install the nuts that attach the driver's seat riser to the floor (Figure 2). Tighten the nuts to 55 ft-lbs (75 N.m). 17. Connect the power driver seat wiring harness connector and attach it to the front riser crossmember (if equipped) (Figure 2). 18. Attach the riser trim shield to the rear of the driver's seat riser with the push-in fasteners (if equipped) (Figure 1). 19. Turn the ignition switch to the "RUN" position. 20. Connect the negative battery cable. 21. From outside the vehicle, turn the ignition switch to the "OFF" position for about 10 seconds and then turn it back to the "RUN" position. 22. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light, or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG ELECTRONIC CONTROL MODULE Dear Ram Van or Wagon Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. DaimlerChrysler Corporation has determined that a defect, which relates to motor vehicle safety, exists in some 1998 Dodge Ram Vans and Wagons. The problem is... If an object impacts the airbag electronic control module (AECM) under the driver's seat of your Ram van or wagon (identified on the enclosed form), the module may inadvertently deploy both airbags. Inadvertent airbag deployment can injure a front seat occupant. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 816 > Feb > 99 > Recall Airbag Electronic Control Module > Page 5988 What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the AECM and install a protective cover over it. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, DC 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. Washington, DC area residents may call 1-202-366-0123. We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. 816 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module Technical Service Bulletin # 816 Date: 990201 Recall - Airbag Electronic Control Module February 1999 Safety Recall No. 816 Airbag Electronic Control Module Models 1998 (AB) Dodge Ram Vans and Wagons NOTE: This recall applies only to vehicles built through June 5, 1998 (MDH 060517). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using the DIAL VIP System. Subject If an object impacts the airbag electronic control module (AECM) on about 46,000 of the above vehicles, the module may inadvertently deploy both airbags. Inadvertent airbag deployment can injure a front seat occupant. Repair The AECM must be replaced and a protective cover must be installed over the new AECM. Part Number Description CCF18160 AECM Package Each package contains the following components: Quantity Description 1 AECM 1 AECM Cover 3 Screws - AECM-to-Floor Pan Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough AECM Packages to service about 25% of those vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced, must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace AECM and install cover 08816182 0.4 hours Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing instructions Parts Return Not required. Dealer Notification & Vehicle List Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module > Page 5994 All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the CMMS and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD816". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed, Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive Last Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Using a trim panel removal tool, remove the push-in fasteners that attach the seat riser trim shield to the rear of the driver's seat riser (if equipped) (Figure 1). Set the trim shield aside. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module > Page 5995 3. Remove the power seat wiring harness connector from the front riser crossmember and then disconnect the connector (if equipped) (Figure 2). 4. Remove the nuts that attach the driver's seat riser to the floor pan (Figure 2). 5. Remove the driver's seat assembly from the vehicle. 6. Disconnect the airbag electronic control module (AECM) wiring connector. 7. Remove the three (3) screws that attach the AECM to the floor pan mounting bracket (Figure 3). Discard the screws. 8. Remove the AECM. Destroy the old AECM connector pins and then discard the old AECM. 9. Install the supplied AECM. Position the AECM on the floor pan mounting bracket with the arrow on the housing pointing forward (Figure 3). 10. Install the three provided AECM mounting screws. Tighten the screws to 105 in-lbs (11.8 N.m). 11. Connect the AECM wiring connector. Make sure that the connector latches are fully engaged. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module > Page 5996 12. Clean the floor pan area around the AECM. 13. Remove the "peel and stick" backing paper from the adhesive strips on the provided AECM cover. 14. Install the cover over the AECM. Press down firmly to ensure that the adhesive strips are securely attached to the floor pan (Figure 4). Note: Position the cover so that the vehicle wiring harnesses are routed through the cover openings. Ensure that the power seat wiring harness is not trapped under the cover. 15. Install the driver's seat assembly into the vehicle. 16. Install the nuts that attach the driver's seat riser to the floor (Figure 2). Tighten the nuts to 55 ft-lbs (75 N.m). 17. Connect the power driver seat wiring harness connector and attach it to the front riser crossmember (if equipped) (Figure 2). 18. Attach the riser trim shield to the rear of the driver's seat riser with the push-in fasteners (if equipped) (Figure 1). 19. Turn the ignition switch to the "RUN" position. 20. Connect the negative battery cable. 21. From outside the vehicle, turn the ignition switch to the "OFF" position for about 10 seconds and then turn it back to the "RUN" position. 22. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light, or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG ELECTRONIC CONTROL MODULE Dear Ram Van or Wagon Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. DaimlerChrysler Corporation has determined that a defect, which relates to motor vehicle safety, exists in some 1998 Dodge Ram Vans and Wagons. The problem is... If an object impacts the airbag electronic control module (AECM) under the driver's seat of your Ram van or wagon (identified on the enclosed form), the module may inadvertently deploy both airbags. Inadvertent airbag deployment can injure a front seat occupant. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control Module > Page 5997 What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the AECM and install a protective cover over it. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, DC 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. Washington, DC area residents may call 1-202-366-0123. We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. 816 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5998 Air Bag Control Module: Locations Module Locations Air Bag Control Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5999 Air Bag Control Module: Diagrams ACM Connector ACM Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 6000 Air Bag Control Module: Description and Operation SYSTEM OPERATION The Airbag Control Module (ACM) is secured to a bracket on the floor panel underneath the driver side front seat in the passenger compartment of the vehicle. The ACM contains a microprocessor that contains the airbag system logic, the impact sensor, and an energy storage capacitor. The ACM system logic includes On-Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry on the Chrysler Collision Detection (CCD) data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the CCD data bus to turn on the airbag indicator lamp. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate signaled by the impact sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the air-bag system components. Only one impact sensor is used in this airbag system. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 6001 Air Bag Control Module: Service and Repair REMOVAL AND INSTALLATION WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - NEVER STRIKE OR KICK THE AIR BAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. ALWAYS REINSTALL THE AIRBAG CONTROL MODULE PROTECTIVE COVER. 1. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Reach under the driver side front seat to access and unplug the wire harness connector from the Air-Bag Control Module (ACM). Airbag Control Module Remove/Install 3. Remove the three screws that secure the ACM to the mounting bracket on the floor panel under the driver seat. 4. Remove the ACM from the floor panel mounting bracket. 5. When installing the ACM, position the unit with the arrow on the ACM housing pointing forward. 6. Secure the ACM to the floor panel mounting bracket with the three mounting screws. Tighten the mounting screws to 11.8 N.m (105 in. lbs.). 7. Plug in the wire harness connector to the ACM. Be certain that the connector latches are fully engaged. 8. Do not connect the battery negative cable at this time. See Airbag System in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: The airbag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the airbag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the airbag and possible personal injury. The fasteners, screws, and bolts, originally used for the airbag components, have special coatings and are specifically designed for the airbag system. They must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books . Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6006 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Tether Installation NUMBER: 23-029-08 GROUP: Body DATE: October 24, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. B, DATED NOVEMBER 24, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DEALERS PLEASE NOTE, THIS IS REIMBURSABLE REGARDLESS OF VEHICLE AGE OR MILEAGE. SUBJECT: Child Seat Tether Anchor Installation OVERVIEW: This bulletin describes procedures to install Child Seat Tether Anchors based on Customer Request. NOTE: Dealers are encouraged to honor any customers request for the installation of the Child Seat Tether Anchors and Dealer reimbursement will be made by Chrysler regardless of vehicle age or mileage. See the Warranty Policy and Procedure Manual and or Warranty Bulletin D-08-33 for reimbursement detail. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shawdow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6012 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year and later. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. Chrysler is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. NOTE: This bulletin is provided to identify the parts and labor operation numbers necessary to install a Child Seat Tether Anchor. Each dealer is encouraged to install these kits based on customer request and Chrysler will reimburse any Chrysler / Dodge / or Jeep dealer installing these kits regardless of vehicle age or mileage. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6013 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6014 PARTS REQUIRED: POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6015 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6016 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6017 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6018 Child Seat Tether Attachment: Technical Service Bulletins Child Seat Tether Anchor - Labor/Parts Identification NUMBER: 23-35-99 Rev. A GROUP: Body DATE: Oct. 1, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-35-99 DATED SEPTEMBER 3, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES IN SOME TIME ALLOWANCES. SUBJECT: Child Seat Tether Anchors NOTE: THIS BULLETIN DOES NOT APPLY TO DAIMLERCHRYSLER CANADA DEALERS. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) LeBaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2000 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light truck in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6019 detailed instruction sheet. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6020 PARTS REQUIRED: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6021 POLICY: Customer Satisfaction Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6022 TIME ALLOWANCE: Failure Code: CG - Customer Satisfaction Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6023 Child Seat Tether Attachment: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6024 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6025 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6026 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6027 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6028 TIME ALLOWANCE: FAILURE CODE: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation SYSTEM OPERATION The seat belt reminder lamp gives a visual reminder to the vehicle occupants to fasten their seat belts. The lamp is turned on by the instrument cluster circuitry for about seven seconds when the ignition switch is turned to the On position. The instrument cluster also receives a hard wired input from the driver seat belt switch. However, this input only affects the chime function and has no effect on the seat belt reminder lamp operation. If the driver seat belt switch is closed (seat belt is not buckled), the instrument cluster will send a chime request to the Central Timer Module (CTM) lasting the duration of the seat belt reminder lamp illumination. The chime warning will stop when the driver seat belt switch is open (seat belt is buckled). The seat belt reminder lamp also serves as a backup for the airbag indicator lamp. About twenty seconds after the ignition switch is turned to the On position, if an inoperative airbag indicator lamp circuit was detected during the bulb test sequence, the instrument cluster circuitry will flash the seat belt reminder lamp on and off for about thirty seconds. If the seat belt reminder lamp stays on after flashing for thirty seconds, or comes on at any time other than about twenty seconds after the initial ignition-on sequence, it indicates an airbag system fault has been detected and that the airbag indicator lamp is inoperative. Refer to Air Bags and Seat Belts/Air Bags for more information on the airbag system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation > Page 6032 Seat Belt Reminder Lamp: Testing and Inspection The diagnosis found here addresses an inoperative seat belt reminder lamp condition. If the lamp comes on and flashes following its display function (about ten seconds after the ignition switch is turned to the On position), it indicates an inoperative airbag indicator lamp. Refer to Restraint Systems/Air Bag Systems/Testing and Inspection for additional testing procedures. See: Air Bag Systems/Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the seat belt reminder lamp fails to light during its normal display function (about six seconds after the ignition switch is turned to the On position), see Instrument Cluster in the Diagnosis and Testing for further diagnosis. This lamp is completely controlled by the instrument cluster circuitry. On models equipped with a Central Timer Module, the hard wired seat belt switch input to the instrument cluster has no control over the seat belt reminder lamp function and is only used by the instrument cluster circuitry as a reference for its chime request function. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6038 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6039 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6040 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6041 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6042 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6043 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6044 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6045 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6046 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6047 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6048 PARTS REQUIRED: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6049 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6050 POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations Passenger Airbag Switch Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations > Page 6053 Passenger Side Airbag On/Off Switch Remove/Install Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6054 Air Bag Deactivation Switch: Diagrams Passenger Airbag Switch Connector Passenger Airbag Switch Connector Passenger Airbag Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6055 Air Bag Deactivation Switch: Service and Repair REMOVAL WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the accessory switch plate from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Accessory Switch Plate Replacement. Passenger Side Airbag On/Off Switch Remove/Install 3. Remove the two screws that secure the passenger airbag disarm switch to the back of the accessory switch plate. 4. Remove the passenger airbag disarm switch from the accessory switch plate. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 6. Do not connect the battery negative cable at this time. See Airbag System in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and Operation Antenna: Description and Operation SYSTEM OPERATION All models use a fixed-length stainless steel rod- type antenna mast, installed at the right front fender of the vehicle. The antenna mast has a spiral groove cut down its length to reduce wind noise. The antenna mast is connected to the center wire of the coaxial antenna cable, and is not grounded to any part of the vehicle. To eliminate static, the antenna base must have a good ground. The coaxial antenna cable shield (the outer wire mesh of the cable) is grounded to the antenna base and the radio chassis. The antenna coaxial cable has an additional disconnect, located on the outboard side of the right instrument panel end bracket and hidden beneath the passenger side instrument panel end cap. This additional disconnect allows the instrument panel assembly to be removed and installed without removing the radio. The factory-installed Electronically Tuned Radios (ETRs) automatically compensate for radio antenna trim. Therefore, no antenna trimmer adjustment is required or possible when replacing the receiver or the antenna. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and Operation > Page 6060 Antenna: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The following four tests are used to diagnose the antenna with an ohmmeter: - Test 1 - Mast to ground test - Test 2 - Tip-of-mast to tip-of-conductor test - Test 3 - Body ground to battery ground test - Test 4 - Body ground to coaxial shield test. Antenna Tests The ohmmeter test lead connections for each test are shown in Antenna Tests. NOTE: This model has a two-piece antenna coaxial cable. Tests 2 and 4 must be conducted in two steps to isolate a coaxial cable problem; from the coaxial cable connection on the right end bracket of the instrument panel near the right cowl side inner panel to the antenna base, and then from the coaxial cable connection to the radio chassis connection. Test 1 Test 1 determines if the antenna mast is insulated from the base. Proceed as follows: 1. Unplug the antenna coaxial cable connector from the radio chassis and isolate. 2. Connect one ohmmeter test lead to the tip of the antenna mast. Connect the other test lead to the antenna base. Check for continuity. 3. There should be no continuity If continuity is found, replace the faulty or damaged antenna base and cable assembly Test 2 Test 2 checks the antenna for an open circuit as follows: 1. Unplug the antenna coaxial cable connector from the radio chassis. 2. Connect one ohmmeter test lead to the tip of the antenna mast. Connect the other test lead to the center pin of the antenna coaxial cable connector. 3. Continuity should exist (the ohmmeter should only register a fraction of an ohm). High or infinite resistance indicates damage to the base and cable assembly Replace the faulty base and cable, if required. Test 3 Test 3 checks the condition of the vehicle body ground connection. This test should be performed with the battery positive cable removed from the battery Disconnect both battery cables, the negative cable first. Reconnect the battery negative cable and perform the test as follows: 1. Connect one ohmmeter test lead to the vehicle fender. Connect the other test lead to the battery negative post. 2. The resistance should be less than one ohm. 3. If the resistance is more than one ohm, check the braided ground strap connected to the engine and the vehicle body for being loose, corroded, or damaged. Repair the ground strap connection, if required. Test 4 Test 4 checks the condition of the ground between the antenna base and the vehicle body as follows: 1. Connect one ohmmeter test lead to the vehicle fender. Connect the other test lead to the outer crimp on the antenna coaxial cable connector. 2. The resistance should be less then one ohm. 3. If the resistance is more then one ohm, clean and/or tighten the antenna base to fender mounting hardware. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and Operation > Page 6061 Antenna: Service and Repair The instrument panel half of the antenna coaxial cable is routed from the right instrument panel end bracket to the radio in a plastic trough with the instrument panel wire harness. The instrument panel wire harness trough is secured to the instrument panel armature. In order to remove the instrument panel half of the antenna coaxial cable from the trough, the instrument panel assembly must be removed from the vehicle. The procedure that follows covers the removal of only the body half of the antenna coaxial cable. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the end cap from the passenger side end of the instrument panel. Refer to Instrument Panel End Cap in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel for the procedures. 3. Roll down the glove box from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Glove Box - Roll Down in the Replacement for the procedures. Antenna Coaxial Cable Connector 4. Unplug the coaxial cable connector. Unplug the connector by pulling it apart while twisting the metal connector halves. Do not pull on the cable. 5. Disengage the retainer for the body half of the coaxial cable from the right instrument panel end bracket. 6. Reach through the glove box opening to access the body half of the coaxial cable and pull it through the space between the right instrument panel end bracket and the dash panel. 7. Reach through the glove box opening to push the coaxial cable grommet through the hole in the dash panel and into the cowl plenum area. 8. Remove the cowl plenum cover/grille panel at the base of the windshield from the cowl top. Refer to Wiper Linkage and Pivot in the Removal and Installation in Wiper and Washer Systems for the procedures. Antenna Mast Remove/Install - Typical 9. Unscrew the antenna mast from the antenna body. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and Operation > Page 6062 Antenna Cap Nut Remove/Install - Typical 10. Remove the antenna cap nut and adapter using an antenna nut wrench (Special Tool C-4816). Antenna Mounting 11. Lower the antenna body and cable assembly through the top of the fender far enough to access the antenna body by reaching through the opening in the right end of the cowl plenum. 12. Remove the antenna body and cable from the cowl plenum. 13. Reverse the removal procedures to install. Tighten the antenna cap nut to 7.3 N.m (65 in. lbs.). Tighten the antenna mast to 3.3 N.m (30 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and Operation > Page 6063 Antenna Nut Wrench C-4816 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Diagrams Door Disarm Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Page 6068 Door Sensor/Switch (For Alarm): Description and Operation SYSTEM OPERATION Door Ajar Switch The door ajar switches are integra to the door latches on each front door. The door ajar switches for the side and rear doors are mounted to the door opening pillars. Each of these switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and open the ground path when a door is closed. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit (front doors) or door ajar switch unit (side or rear doors) must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Page 6069 Door Sensor/Switch (For Alarm): Service and Repair REMOVAL Front Door The front door ajar switches are integral to the front door latch unit. If a front door ajar switch is faulty or damaged, the entire front door latch unit must be replaced. Side Or Rear Door 1. Disconnect and isolate the battery negative cable. Door Ajar Switch Remove/Install - Side Or Rear Door 2. Unscrew the door ajar switch from the pillar. 3. Pull the door ajar switch away from the pillar far enough to access and unplug the two wire harness connectors from the switch. 4. Remove the door ajar switch from the vehicle. 5. Reverse the removal procedures to install. Tighten the switch to 5.6 N.m (50 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair A power lock and Remote Keyless Entry (RKE) module is only used on high-line versions of this vehicle that are not equipped with the optional Vehicle Theft Security System (VTSS). Models equipped with the optional VTSS have the power lock and RKE functions controlled by the Central Timer Module (CTM). See Power Lock System and Remote Keyless Entry System in the General Information for more information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the engine cover from the passenger compartment. Power Lock And Remote Keyless Entry Module Remove/Install 3. Remove the two screws that secure the power lock and RKE module to the inboard side of the left center instrument panel support. 4. Pull the power lock and RKE module away from its mounting location far enough to access and unplug the two wire harness connectors. 5. Remove the power lock and RKE module from the instrument panel. 6. Reverse the removal procedures to install. Tighten the mounting screws to 3.3 N.m (30 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Programming Connector > Component Information > Locations 16-Way Data Link Connector - Typical Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Description and Operation Keyless Entry Receiver: Description and Operation SYSTEM OPERATION The Remote Keyless Entry (RKE) receiver is a radio frequency unit that is integral to the power lock and RKE module or to the Central Timer Module (CTM). The RKE receiver has a memory function to retain the vehicle access codes of the RKE transmitters, even if the battery is disconnected. The power lock and RKE module can store two transmitter vehicle access codes, the CTM can store up to four. The RKE receiver is energized by one of two radio frequency inputs from the RKE transmitter, Unlock or Lock. The programming of the power lock and RKE module or the CTM responds to these RKE inputs, as well as many other inputs, by sending the proper control outputs to the power lock motors, the courtesy lamp circuit, and (with the CTM-based RKE system only) the horn relay. The RKE receiver is only serviced as a unit with the power lock and RKE module or the CTM and, if faulty or damaged, the module unit must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure Keyless Entry Transmitter Battery: Customer Interest RKE Transmitter - Premature Battery Failure NO: 08-39-97 GROUP: Electrical DATE: Nov. 28, 1997 SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely MODELS: 1997 - 1998 (AB) Ram Van/Wagon 1997 - 1998 (AN) Dakota/Dakota Cab & Chassis 1998 (BRIBE)Ram Truck 1998 (DN) Durango 1997 (LH) Concorde/Intrepid/LHS/Vision 1997 - 1998 (NS) Town & Country/Caravan/Voyager 1997 - 1998 (PL) Neon 1997 (PR) Prowler 1997 - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX). SYMPTOM/CONDITION: Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH 0815XX, perform the Repair Procedure. PARTS REQUIRED: AR 04686366 Transmitter, RKE- NS, PL & PR AR 04759136AB Transmitter, RKE- LH AR 56007049 Transmitter, RKE- AB & 1997 AN AR 56008761 Transmitter 1, RKE- ZJ & DN AR 56008762 Transmitter 2, RKE- ZJ AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitter(s). 1. Replace RKE transmitter(s) that have discharged batteries. 2. Program the RKE transmitter(s) to the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-28-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure Keyless Entry Transmitter Battery: All Technical Service Bulletins RKE Transmitter - Premature Battery Failure NO: 08-39-97 GROUP: Electrical DATE: Nov. 28, 1997 SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely MODELS: 1997 - 1998 (AB) Ram Van/Wagon 1997 - 1998 (AN) Dakota/Dakota Cab & Chassis 1998 (BRIBE)Ram Truck 1998 (DN) Durango 1997 (LH) Concorde/Intrepid/LHS/Vision 1997 - 1998 (NS) Town & Country/Caravan/Voyager 1997 - 1998 (PL) Neon 1997 (PR) Prowler 1997 - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX). SYMPTOM/CONDITION: Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH 0815XX, perform the Repair Procedure. PARTS REQUIRED: AR 04686366 Transmitter, RKE- NS, PL & PR AR 04759136AB Transmitter, RKE- LH AR 56007049 Transmitter, RKE- AB & 1997 AN AR 56008761 Transmitter 1, RKE- ZJ & DN AR 56008762 Transmitter 2, RKE- ZJ AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitter(s). 1. Replace RKE transmitter(s) that have discharged batteries. 2. Program the RKE transmitter(s) to the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-28-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > Page 6094 Keyless Entry Transmitter Battery: Service and Repair The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry at the center seam of the transmitter case halves near the key ring until the two halves unsnap. 2. Lift the back half of the transmitter case off of the transmitter. 3. Remove the two batteries from the transmitter. 4. Replace the two batteries with new Duracell DL2016, or their equivalent. Be certain that the batteries are installed with their polarity correctly oriented. 5. Align the two transmitter case halves with each other, and squeeze them firmly together until they snap back into place. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Description and Operation Lock Cylinder Switch: Description and Operation SYSTEM OPERATION The door lock cylinder switches are mounted to the back of the key lock cylinder inside each front door. They are normally-open momentary witches that close to ground only when the lock cylinder is rotated to the unlock position. The door lock cylinder switches cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Description and Operation > Page 6098 Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the front door. Door Lock Cylinder Switch Remove/Install 3. Unplug the door lock cylinder switch wire harness connector. 4. Disengage the door lock cylinder switch from the back of the front door lock cylinder 5. Disengage the retainers that secure the door lock cylinder switch wire harness to the inner door panel. 6. Remove the door lock cylinder switch from the door. 7. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Description and Operation Security Lamp/Indicator: Description and Operation SYSTEM OPERATION The security lamp gives an indication of the status of the optional Vehicle Theft Security System (VTSS). The lamp is controlled by a hard wired input to the instrument cluster from the high-line Central Timer Module (CTM). The lamp is turned on by the CTM for about two seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the CTM turns the lamp on or off based upon the arming status of the VTSS. If the security lamp stays on for about thirty seconds after the ignition switch is turned to the On position, it indicates that Chrysler Collision Detection (CCD) data bus communication with the Powertrain Control Module (PCM) is inoperative, and that the next attempt to arm the VTSS may not be successful. Refer to Accessories and Optional Equipment/Antitheft and Alarm/Vehicle Theft/Security Systems for more information on the VTSS and the security lamp. The security lamp is an amber lamp located within the instrument cluster on the instrument panel. The security lamp receives fused battery feed at all times and is grounded by the high line Central Timer Module (CTM) to give a visible indication of the Vehicle Theft Security System (VTSS) arming status. The security lamp incandescent bulb and bulb holder can be serviced. Refer to Instrument Panel, Gauges and Warning Indicators/Cluster Bulbs Service Procedures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Description and Operation > Page 6102 Security Lamp/Indicator: Testing and Inspection The diagnosis found here addresses an inoperative security lamp condition. If the problem being diagnosed is an inaccurate security lamp, refer to Accessories and Optional Equipment/Antitheft and Alarm System/Vehicle Theft/Security Systems for diagnosis of the Vehicle Theft Security System ( VTSS). WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the Power Distribution Center (PDC). If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the PDC. If OK, go to Step 4. If not OK, repair the open circuit to the battery as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM). Unplug the CTM wire harness connectors. Connect the battery negative cable. Install a jumper wire between the security indicator control circuit cavity of the 18-way CTM wire harness connector and a good ground. The security lamp should light. If OK, use a DRB scan tool and the proper Diagnostic Procedures to diagnose the Vehicle Theft Security System (VTSS) and the CTM. If not OK, go to Step 5. 4. Disconnect and isolate the battery negative cable. Remove the instrument cluster. Check for continuity between the fused B(+) circuit cavity of the instrument cluster wire h ness connector (connector A) and the fuse in the PDC. There should be continuity If OK, go to Step 6. If not OK, repair the open circuit to the PDC as required. 5. Check for continuity between the security indicator control circuit cavities of the instrument cluster wire harness connector (connector A) and the 18-way CTM wire harness connector. There should be continuity. If OK, see Instrument Cluster in the Diagnosis and Testing for further diagnosis of the security lamp and the instrument cluster circuitry. If not OK, repair the open circuit as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6107 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6108 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6109 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6114 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6115 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6116 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair Amplifier: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the end cap from the passenger side end of the instrument panel. Refer to Instrument Panel End Cap in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel for the procedures. 3. Roll down the glove box from the instrument panel. Refer to Glove Box - Roll Down in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel for the procedures. 4. Reach through the outboard side of the glove box opening to access and unplug the two wire harness connectors from the lower end of the amplifier. Amplifier Remove/Install 5. Reach through the outboard side of the glove box opening to support the amplifier while removing the two screws that secure the amplifier from the outboard side of the right instrument panel end bracket. 6. Lift the amplifier upwards far enough to disengage the mounting tab from the slot in the lower rear corner of the right instrument panel end bracket. 7. Remove the amplifier through the instrument panel glove box opening. 8. Reverse the removal procedures to install. Tighten the mounting screws to 3.3 N.m (30 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > CD Player - CD Compatibility Compact Disc Player (CD): Technical Service Bulletins CD Player - CD Compatibility BULLETIN NUMBER: 08-11-00 GROUP: Electrical DATE: March 24, 2000 SUBJECT: Recordable Compact Discs Used in Automotive CD players MODELS: 1989 - 2000 (AB) Ram Van/Wagon 1989 - 2000 (AN) Dakota 1994 - 2000 (BR/BE) Ram Truck 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GT 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee DISCUSSION: Some recordable compact disc media, such as CD-R and CD-RW, may not comply with the standard CD format used in automotive CD players. When these CD's are used, customers may encounter error messages, skipping, or delaminating of the labels, which can cause an eject failure. It is important to question whether these kinds of CD media are being used. When customers encounter these symptoms, check the system with a known playable CD. Explain that the media may not be compatible with some automotive CD players. Replacing or exchanging the CD player will not address these issues. POLICY: Information Only Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions Radio/Stereo: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6129 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6130 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6131 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6134 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6135 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6136 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6137 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6138 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6139 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6140 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6141 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6142 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6143 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6144 Radio/Stereo: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6145 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6146 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6147 Radio/Stereo: Electrical Diagrams Base 8w-47-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6148 8w-47-3 NOTE: To view Diagrams referred to in these diagrams SEE Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Premium Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6149 8w-47-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6150 8w-47-4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6151 8w-47-5 NOTE: To view Diagrams referred to in these diagrams SEE Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 6152 Radio/Stereo: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. CAUTION: The speaker output of the radio is a "floating ground" system. Do not allow any speaker lead to short to ground, as damage to the radio may result. 1. Check the fuse(s) in the junction block and the Power Distribution Center (PDC). If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse(s). 2. Check for battery voltage at the fuse in the PDC. If OK, go to Step 4. If not OK, repair the open circuit to the battery as required. 3. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 5. If not OK, repair the open circuit to the ignition switch as required. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the radio, but do not unplug the radio wire harness connectors. Check for continuity between the radio chassis and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open radio chassis ground circuit as required. 5. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (accessory/run) circuit cavity of the left (gray) radio wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit as required. 6. Turn the ignition switch to the Off position. Check for battery voltage at the fused B(+) circuit cavity of the left (gray) radio wire harness connector. If OK, replace the faulty radio. If not OK, repair the open circuit to the Ignition-Off Draw (IOD) fuse as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 6153 Radio/Stereo: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. Refer to Cluster Bezel in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel for the procedures. Radio Remove/Install 3. Remove the two screws that secure the radio to the instrument panel. CAUTION: Care must be used when removing or installing the radio so as not to damage the accessory switch plate, which is located just to the right of the radio and the heater-air conditioner controls in the instrument panel. Radio Connections - Typical 4. Pull the radio out from the instrument panel far enough to access the wire harness connectors and the antenna coaxial cable connector. 5. Unplug the wire harness connectors and the antenna coaxial cable connector from the rear of the radio. 6. Remove the radio from the instrument panel. 7. Reverse the removal procedures to install. Thghten the radio mounting screws to 3.3 N.m (30 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation Speaker: Description and Operation SYSTEM OPERATION The standard equipment speaker system includes speakers in four locations. One full-range 8.9 centimeter (3.50 inch) diameter speaker is located in each end of the instrument panel top cover, and one full-range 15.2 by 22.9 centimeter (6.00 by 9.00 inch) speaker is located in each front door. An optional six speaker stereo system adds one full-range 15.2 by 22.9 centimeter (6.00 by 9.00 inch) speaker to each side panel of the vehicle, near the rear wheel housings. The optional premium speaker system replaces the speakers used in the six speaker stereo system with six Infinity model speakers in the same six locations, and includes a 120 watt amplifier. The Infinity amplifier is mounted to the inboard side of the right instrument panel end bracket, outboard of the glove box opening. The amplifier is accessed for service by rolling the glove box down from the instrument panel. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Page 6157 Speaker: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. CAUTION: The speaker output of the radio is a "floating ground" system. Do not allow any speaker lead to short to ground, as damage to the radio may result. 1. Turn the ignition switch to the On position. Turn the radio on. Adjust the balance and fader controls to check the performance of each individual speaker. Note the speaker locations that are not performing correctly. Go to Step 3. 2. Turn the radio off. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the radio from the instrument panel. If the vehicle is equipped with the Infinity speaker package, also unplug the wire harness connectors at the amplifier. Check both the speaker feed (+) circuit and return (-) circuit cavities for the inoperative speaker location(s) at the radio wire harness connectors for continuity to ground. In each case, there should be no continuity. If OK, go to Step 4. If not OK, repair the shorted speaker circuit(s) as required. 3. If the vehicle is equipped with the Infinity speaker package, go to Step 7. If the vehicle is equipped with the standard speaker system, check the resistance between the speaker feed (+) circuit and return (-) circuit cavities of the radio wire harness connectors for the inoperative speaker location(s). The meter should read between 2 and 12 ohms (speaker resistance). If OK, go to Step 5. If not OK, go to Step 6. 4. Install a known good radio. Connect the battery negative cable. Turn the ignition switch to the On position. Turn on the radio and test the speaker operation. If OK, replace the faulty radio. If not OK, turn the radio on turn the ignition switch to the Off position, disconnect and isolate the battery negative cable, remove the test radio, and go to Step 6. 5. Unplug the speaker wire harness connector at the inoperative speaker. Check for continuity between the speaker feed (+) circuit cavities of the radio wire harness connector and the speaker wire harness connector. Repeat the check between the speaker return (-) circuit cavities of the radio wire harness connector and the speaker wire harness connector. In each case, there should be continuity If OK, replace the faulty speaker. If not OK, repair the open circuit(s) as required. 6. For each inoperative speaker location, check for continuity between the speaker feed (+) circuit cavities of the radio wire harness connectors and the amplifier wire harness connectors. Repeat the check for each inoperative speaker location between the speaker return (-) circuit cavities of the radio wire harness connectors and the amplifier wire harness connectors. In each case, there should be continuity. If OK, go to Step 8. If not OK, repair the open circuit as required. 7. Check for continuity between the two ground circuit cavities of the amplifier wire harness connector and a good ground. There should be continuity. If OK, go to Step 9. If not OK, repair the open circuit(s) as required. 8. Check the amplifier fuse in the junction block. If OK, go to Step 10. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 9. Install the radio. Connect the battery negative cable. Check for battery voltage at the amplifier fuse in the junction block. If OK, go to Step 11. If not OK, repair the open circuit to the PDC as required. 10. Check for battery voltage at the two fused B(+) circuit cavities of the amplifier wire harness connector. If OK, go to Step 12. If not OK, repair the open circuit to the fuse in the junction block as required. 11. Turn the ignition switch to the On position. Turn the radio on. Check for battery voltage at the radio 12 volt output circuit cavity of the amplifier wire harness connector. If OK, go to Step 3. If not OK, repair the open circuit to the radio as required. 12. Turn the radio off. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. For each inoperative speaker location, check both the amplified feed (+) circuit and the amplified return (-) circuit cavities of the amplifier wire harness connectors for continuity to ground. In each case there should be no continuity If OK, go to Step 14. If not OK, repair the short circuit as required. 13. For each inoperative speaker location, check the resistance between the amplified feed (+) circuit and the amplified return (-) circuit cavities of the amplifier wire harness connectors. The meter should read between 2 and 12 ohms (speaker resistance). If OK, replace the faulty amplifier. If not OK, go to Step 15. 14. Unplug the speaker wire harness connector at the inoperative speaker. Check for continuity between the amplified feed (+) circuit cavities of the speaker wire harness connector and the amplifier wire harness connector. Repeat the check between the amplified return (-) circuit cavities of the speaker wire harness connector and the amplifier wire harness connector. In each case there should be continuity If OK, replace the faulty speaker. If not OK, repair the open circuit as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Page 6158 Speaker: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the top cover from the instrument panel. Refer to Instrument Panel Top Cover in the Removal and Installation Instrument Panel, Gauges and Warning Indicators/Instrument Panel for the procedures. Instrument Panel Speaker Remove/Install 3. Remove the two screws that secure the speaker to the top of the instrument panel. 4. Pull the speaker away from the top of the instrument panel far enough to access and unplug the speaker wire harness connector. 5. Remove the speaker from the instrument panel. 6. Reverse the removal procedures to install. Tighten the mounting screws to 2 N.m (17 in. lbs.). Front Door 1. Disconnect and isolate the battery negative cable. 2. Remove the inside trim panel from the front door. Front Door Speaker Remove/Install 3. Remove the three screws that secure the speaker to the front door inner panel. 4. Pull the speaker away from the front door inner panel far enough to access and unplug the speaker wire harness connector. 5. Remove the speaker from the front door. 6. Reverse the removal procedures to install. Tighten the mounting screws to 4 N.m (35 in. lbs.). Rear Panel Without Cargo Compartment Trim 1. Disconnect and isolate the battery negative cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Page 6159 Rear Panel Speaker Remove/Install - Without Cargo Compartment Trim 2. Remove the four screws that secure the speaker mounting bracket to the rear panel reinforcements. 3. Pull the speaker mounting bracket away from the rear panel reinforcements far enough to access and unplug the speaker wire harness connector. 4. Remove the four nuts that secure the grille from the rear of the speaker mounting bracket. 5. Remove the grille from the front of the speaker mounting bracket. 6. Remove the four screws that secure the speaker from the front of the speaker mounting bracket. 7. Remove the speaker from the rear of the speaker mounting bracket. 8. Reverse the removal procedures to install. Tighten all of the mounting hardware to 2.2 N.m (20 in. lbs.). With Cargo Compartment Trim 1. Disconnect and isolate the battery negative cable. 2. Remove the inside trim panel from the rear panel. Rear Panel Speaker Remove/Install - With Cargo Compartment Trim 3. Remove the four nuts that secure the grille from the rear of the trim panel. 4. Remove the grille from the front of the trim panel. 5. Remove the four screws that secure the speaker from the front of the trim panel. 6. Remove the speaker from the rear of the trim panel. 7. Reverse the removal procedures to install. Tighten all of the mounting hardware to 2.2 N.m (20 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair A power lock and Remote Keyless Entry (RKE) module is only used on high-line versions of this vehicle that are not equipped with the optional Vehicle Theft Security System (VTSS). Models equipped with the optional VTSS have the power lock and RKE functions controlled by the Central Timer Module (CTM). See Power Lock System and Remote Keyless Entry System in the General Information for more information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the engine cover from the passenger compartment. Power Lock And Remote Keyless Entry Module Remove/Install 3. Remove the two screws that secure the power lock and RKE module to the inboard side of the left center instrument panel support. 4. Pull the power lock and RKE module away from its mounting location far enough to access and unplug the two wire harness connectors. 5. Remove the power lock and RKE module from the instrument panel. 6. Reverse the removal procedures to install. Tighten the mounting screws to 3.3 N.m (30 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams Door Disarm Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Page 6168 Door Sensor/Switch (For Alarm): Description and Operation SYSTEM OPERATION Door Ajar Switch The door ajar switches are integra to the door latches on each front door. The door ajar switches for the side and rear doors are mounted to the door opening pillars. Each of these switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and open the ground path when a door is closed. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit (front doors) or door ajar switch unit (side or rear doors) must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Page 6169 Door Sensor/Switch (For Alarm): Service and Repair REMOVAL Front Door The front door ajar switches are integral to the front door latch unit. If a front door ajar switch is faulty or damaged, the entire front door latch unit must be replaced. Side Or Rear Door 1. Disconnect and isolate the battery negative cable. Door Ajar Switch Remove/Install - Side Or Rear Door 2. Unscrew the door ajar switch from the pillar. 3. Pull the door ajar switch away from the pillar far enough to access and unplug the two wire harness connectors from the switch. 4. Remove the door ajar switch from the vehicle. 5. Reverse the removal procedures to install. Tighten the switch to 5.6 N.m (50 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Description and Operation Lock Cylinder Switch: Description and Operation SYSTEM OPERATION The door lock cylinder switches are mounted to the back of the key lock cylinder inside each front door. They are normally-open momentary witches that close to ground only when the lock cylinder is rotated to the unlock position. The door lock cylinder switches cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Description and Operation > Page 6173 Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the front door. Door Lock Cylinder Switch Remove/Install 3. Unplug the door lock cylinder switch wire harness connector. 4. Disengage the door lock cylinder switch from the back of the front door lock cylinder 5. Disengage the retainers that secure the door lock cylinder switch wire harness to the inner door panel. 6. Remove the door lock cylinder switch from the door. 7. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6179 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6180 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6181 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6182 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6183 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6184 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6185 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6186 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6187 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6188 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6189 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6190 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6191 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6192 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6193 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6194 Trailer Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6195 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6196 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6201 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6202 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6203 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6204 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6205 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6206 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6207 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6208 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6209 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6210 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6211 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6212 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6213 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6214 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6215 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6216 Trailer Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6217 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6218 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Component Locations Module Locations Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 6225 Central Timer Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6228 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6229 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6230 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6231 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6232 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6233 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6234 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6235 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6236 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6237 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6238 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6239 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6240 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6241 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6242 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6243 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6244 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6245 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6246 Body Control Module: Connector Views CTM Connector CTM Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6247 Body Control Module: Electrical Diagrams Central Timer Module Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6248 Vehicle Communications Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Central Timer Module Description Body Control Module: Description and Operation Central Timer Module Description The AB HIGH LINE utilize a Central Timer Module (CTM). The Base AB RAM VAN will not be addressed in this manual. For concerns about the Base AB VAN, please refer to the appropriate service and repair article. The CTM performs most of the typical functions a Body Control Module would perform. The CTM provides the following features: - Remote Keyless Entry (RKE) - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks WIRKE - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Vehicle Theft Security System (VTSS) The module is located on the left center instrument panel support. It contains a white 18-way and a green 14-way connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Central Timer Module Description > Page 6251 Body Control Module: Description and Operation System Description and Functional Operation The body system on the 1998 AB HIGH LINE consists of three modules that communicate over the CCD bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-Lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication. The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are performed through the Serial Communication Interface of SCI, the same as previous years. All of the information about the functioning of all the system is organized, controlled, and communicated by the CCD bus, which is described in Section 3 (CCD Bus) of this general information section. Through the CCD bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all the information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics Identification of Systems The vehicle Systems that are part of the "body" system are: - Airbag System (ACM) - Central Timer Module (CTM) - Instrument Cluster (MIC) - Vehicle Communication Diagnostic Strategies Diagnosis of the central timer module (CTM) is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem verification of proper operation Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair Access Cover: Service and Repair NOTE: The engine cover is attached with screws at the rear and with latches at the dash extension. REMOVAL 1. Remove screws attaching holddown brackets to floor pan. 2. Disengage latches from dash extension. 3. Remove engine cover from vehicle. INSTALLATION 1. Position engine cover on floor pan. 2. Ensure seal is seated correctly. 3. Position holddown brackets on cover and install screws in floor pan finger tight. 4. Engage latches with dash panel extension. 5. Tighten screws attaching cover to floor pan. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Raise window glass to closed position. 2. Remove the waterdam. Refer to Front Door Panel. Fig. 7 3. Remove nuts attaching outside handle to door (Fig. 7). 4. Disconnect handle latch rod from latch. 5. Separate handle from door. INSTALLATION 1. Position handle on door. 2. Install nuts attaching door handle to door. 3. Connect handle latch rod to latch. 4. Install the waterdam. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the front door. Power Window Motor Remove/Install 3. Disengage the power window motor wire harness connector retainer from the mounting hole on the front door module and unplug the connector. 4. Remove the three screws that secure the power window motor and mechanism to the front door module. 5. Remove the power window motor and mechanism from the front door module. 6. Reverse the removal procedures to install. Tighten the mounting screws to 11 N.m (98 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Exterior Handle > System Information > Service and Repair > Rear Cargo Doors Rear Door Exterior Handle: Service and Repair Rear Cargo Doors EXTERIOR HANDLE REMOVAL 1. Open the rear cargo door. 2. Remove the trim panel from the door inner panel. Fig. 4 Fig. 5 3. Disconnect the outside door handle rod from the latch lever (Fig. 4) and (Fig. 5). 4. Remove the nuts that attach the handle to the door outer panel. Remove the handle from the door. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Exterior Handle > System Information > Service and Repair > Rear Cargo Doors > Page 6272 INSTALLATION 1. Position the handle on the door outer panel with the handle rod inserted in the opening. Insert the handle studs into the panel holes. 2. Attach the handle rod to the latch. 3. Install the nuts that attach the handle to the door outer panel. 4. Install the door trim panel. REAR CARGO DOOR OUTSIDE HANDLE/LATCH LEVER 1. Insert a 4 mm (5/32 in.) hex-wrench through the adjustment slot and into the latch release lever adjustment screw. Loosen the adjustment screw. 2. Depress and release the door outside handle latch release button several times. 3. Tighten the adjustment screw to 3 N.m (30 in. lbs.) torque. 4. Test the door handle for correct operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Exterior Handle > System Information > Service and Repair > Rear Cargo Doors > Page 6273 Rear Door Exterior Handle: Service and Repair Dual Cargo Doors EXTERIOR HANDLE REMOVAL 1. Open the cargo doors. 2. Remove the trim panel from the right door. Fig. 4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Exterior Handle > System Information > Service and Repair > Rear Cargo Doors > Page 6274 Fig. 5 3. Disconnect the outside handle latch rod from the latch lever (Fig. 4) and (Fig. 5). 4. Remove the nuts that attach the handle to the door panel. Remove the handle from the door. INSTALLATION 1. Position the handle on the door panel with the handle latch rod inserted in the opening. Insert the handle studs into the panel holes. 2. Attach the handle latch rod to the latch lever. 3. Install the nuts that attach the handle to the door panel. 4. Install the door trim panel. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Technical Service Bulletins > Customer Interest for Sliding Door Handle: > 23-40-98 > Sep > 98 > Side/Rear Cargo Door - Outside Handle(s) Loose Sliding Door Handle: Customer Interest Side/Rear Cargo Door - Outside Handle(s) Loose NO: 23-40-98 GROUP: Body DATE: Sep. 4, 1998 SUBJECT: Side And/Or Rear Cargo Door Outside Handle(s) Loose MODELS: 1998 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE MAY 16, 1998 (MDH 0516XX). SYMPTOM/CONDITION: Side and/or rear cargo door outside handle(s) are loose. DIAGNOSIS: Inspect the side and rear cargo door handles to verify handle looseness. If either the side and/or rear cargo door handle(s) is/are loose, perform the Repair Procedure. PARTS REQUIRED: AR (1) 04318031 Adhesive, Lock & Seal AR (1) 55075654 Handle, Dual Cargo Door AR (1) 55359037AA Handle, Single Rear Cargo Door AR (1) J4200306 Nut, Door Handle Retaining REPAIR PROCEDURE: This bulletin involves adding Mopar Lock & Seal Adhesive to the threads of the door handle stud and nut. 1. Open the cargo door(s). 2. Remove the inside door handle retaining screw and separate the handle from the vehicle. 3. Remove the inside door handle trim bezel. This can be accomplished by inserting trim sticks in the upper half of the trim bezel. Then, gently tapping on the upper bezel half with a plastic mallet until it is released from the trim bezel. Remove the upper bezel from the trim and then tap the lower trim bezel upward. 4. Use a trim removal tool to pry the trim panel away from the door inner panel. 5. Separate the trim panel away from the door. 6. Remove the nuts that attach the outside door handle to the door panel. 7. Apply a small amount of Mopar Lock & Seal p/n 04318031 to the threads of the nuts. Then, install the nuts onto the outside door handle. Tighten the nuts to 2.8 Nm (25 in.lbs.). NOTE: IF THE STUDS ON THE OUTSIDE DOOR HANDLE ARE BROKEN, REPLACE THE DOOR HANDLE AND ATTACHING NUTS (SEE PARTS REQUIRED SECTION). USE MOPAR LOCK & SEAL PIN 04318031 ON THE THREADS OF THE NUTS WHEN INSTALLING THE HANDLE. REFER TO THE 1998 RAM VAN SERVICE MANUAL (PUBLICATION NO.81-370-8107), PAGE 23-44 FOR DUAL CARGO DOOR OUTSIDE HANDLE REMOVAL AND INSTALLATION PROCEDURES OR PAGES 23-49 AND 23-50 FOR A SINGLE REAR CARGO DOOR OUTSIDE HANDLE REMOVAL AND INSTALLATION PROCEDURES. 8. Position the trim panel onto the inner door panel. 9. Push inward and force the clip retainers into the door panel holes. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Technical Service Bulletins > Customer Interest for Sliding Door Handle: > 23-40-98 > Sep > 98 > Side/Rear Cargo Door - Outside Handle(s) Loose > Page 6284 10. Insert the lower trim bezel half into the door handle opening and seat it in place. 11. Insert the upper bezel half into the door handle opening and seat it in place. 12. Install the inside door handle. Tighten the screw to 11 Nm (95 in.lbs.). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-42-15-97 Apply Adhesive To The Outside Cargo Door Handle Nut Threads - One 0.2 Hrs. 23-42-15-98 Remove And Install Outside Cargo Door Handle And Apply Adhesive To The Outside Cargo Door Handle Nut Threads One 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Handle: > 23-40-98 > Sep > 98 > Side/Rear Cargo Door - Outside Handle(s) Loose Sliding Door Handle: All Technical Service Bulletins Side/Rear Cargo Door - Outside Handle(s) Loose NO: 23-40-98 GROUP: Body DATE: Sep. 4, 1998 SUBJECT: Side And/Or Rear Cargo Door Outside Handle(s) Loose MODELS: 1998 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE MAY 16, 1998 (MDH 0516XX). SYMPTOM/CONDITION: Side and/or rear cargo door outside handle(s) are loose. DIAGNOSIS: Inspect the side and rear cargo door handles to verify handle looseness. If either the side and/or rear cargo door handle(s) is/are loose, perform the Repair Procedure. PARTS REQUIRED: AR (1) 04318031 Adhesive, Lock & Seal AR (1) 55075654 Handle, Dual Cargo Door AR (1) 55359037AA Handle, Single Rear Cargo Door AR (1) J4200306 Nut, Door Handle Retaining REPAIR PROCEDURE: This bulletin involves adding Mopar Lock & Seal Adhesive to the threads of the door handle stud and nut. 1. Open the cargo door(s). 2. Remove the inside door handle retaining screw and separate the handle from the vehicle. 3. Remove the inside door handle trim bezel. This can be accomplished by inserting trim sticks in the upper half of the trim bezel. Then, gently tapping on the upper bezel half with a plastic mallet until it is released from the trim bezel. Remove the upper bezel from the trim and then tap the lower trim bezel upward. 4. Use a trim removal tool to pry the trim panel away from the door inner panel. 5. Separate the trim panel away from the door. 6. Remove the nuts that attach the outside door handle to the door panel. 7. Apply a small amount of Mopar Lock & Seal p/n 04318031 to the threads of the nuts. Then, install the nuts onto the outside door handle. Tighten the nuts to 2.8 Nm (25 in.lbs.). NOTE: IF THE STUDS ON THE OUTSIDE DOOR HANDLE ARE BROKEN, REPLACE THE DOOR HANDLE AND ATTACHING NUTS (SEE PARTS REQUIRED SECTION). USE MOPAR LOCK & SEAL PIN 04318031 ON THE THREADS OF THE NUTS WHEN INSTALLING THE HANDLE. REFER TO THE 1998 RAM VAN SERVICE MANUAL (PUBLICATION NO.81-370-8107), PAGE 23-44 FOR DUAL CARGO DOOR OUTSIDE HANDLE REMOVAL AND INSTALLATION PROCEDURES OR PAGES 23-49 AND 23-50 FOR A SINGLE REAR CARGO DOOR OUTSIDE HANDLE REMOVAL AND INSTALLATION PROCEDURES. 8. Position the trim panel onto the inner door panel. 9. Push inward and force the clip retainers into the door panel holes. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Handle: > 23-40-98 > Sep > 98 > Side/Rear Cargo Door - Outside Handle(s) Loose > Page 6290 10. Insert the lower trim bezel half into the door handle opening and seat it in place. 11. Insert the upper bezel half into the door handle opening and seat it in place. 12. Install the inside door handle. Tighten the screw to 11 Nm (95 in.lbs.). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-42-15-97 Apply Adhesive To The Outside Cargo Door Handle Nut Threads - One 0.2 Hrs. 23-42-15-98 Remove And Install Outside Cargo Door Handle And Apply Adhesive To The Outside Cargo Door Handle Nut Threads One 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > Customer Interest for Sliding Door Latch: > 23-15-00 > Apr > 00 > Sliding Door - Will Not Open And/Or Close/Latch Sliding Door Latch: Customer Interest Sliding Door - Will Not Open And/Or Close/Latch NUMBER: 23-15-00 GROUP: Body DATE: April 21, 2000 SUBJECT: Sliding Door Will Not Open And/Or Close/Latch MODELS: 1998 - 2000 (AB) Ram Van/Wagon OVERVIEW: This bulletin involves installing revised sliding door rear latch assembly and latch rods and modifying the rear latch opening. NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE SLIDING SIDE DOOR (SALES CODE GKF) BUILT BEFORE FEBRUARY 26,2000 (MDH 0226XX). SYMPTOM/CONDITION: The sliding door will not open and/or will not close/latch. DIAGNOSIS: DOOR WILL NOT OPEN 1. Remove the sliding door trim panel attaching screws. 2. Remove the door pull handle (Figure 1). 3. Using a trim removal tool, carefully pry the trim panel away from the door inner panel. 4. Separate the trim panel from the sliding door. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > Customer Interest for Sliding Door Latch: > 23-15-00 > Apr > 00 > Sliding Door - Will Not Open And/Or Close/Latch > Page 6299 5. Remove the sliding door inside handle attaching screw (Figure 2). 6. Remove the inside sliding door handle and spacers. 7. Remove the lock knob from the knob latch rod. 8. Remove the latch cover screws from the door panel. 9. Remove the cover from the door panel. 10. Inspect the front latch-to-rear latch control rod. If the rod is positioned as shown in Figure 3, the rear latch has over-traveled and jammed. Use a screwdriver to pry the latch rod rearward to dislodge the latch rod. A dislodged rod can be identified by the rod being free to move fore and aft by grasping the rod with your hand. If the rod is not positioned as shown in Figure 3, this bulletin will not correct a door that will not open complaint. Further diagnosis is required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > Customer Interest for Sliding Door Latch: > 23-15-00 > Apr > 00 > Sliding Door - Will Not Open And/Or Close/Latch > Page 6300 11. Remove the rear door latch attaching screws (Figure 4). 12. With the rear latch loose, push open the rear of the door enough to disconnect the rear latch rods (Figure 5). 13. Remove the rear latch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > Customer Interest for Sliding Door Latch: > 23-15-00 > Apr > 00 > Sliding Door - Will Not Open And/Or Close/Latch > Page 6301 14. Inspect the rear latch reinforcement on the rear latch opening of the inner door panel for a high trim condition as shown in Figure 6. If the reinforcement sticks up higher than the opening, perform the Repair Procedure. If the rod is not positioned as shown in Figure 3 and/or the latch reinforcement does not stick up higher than the opening, this bulletin will not correct a door that will not open complaint. Further diagnosis is required. DOOR WILL NOT CLOSE/LATCH 1. Remove the sliding door trim panel attaching screws. 2. Remove the door pull handle (Figure 1). 3. Using a trim removal tool, carefully pry the trim panel away from the door inner panel. 4. Separate the trim panel from the sliding door. 5. Inspect the front latch-to-rear latch control rod to ensure that the rod clips are attached. Perform the Repair Procedure if the rod clips are not attached. 6. Disconnect both front latch-to-rear latch control rods. 7. Remove the rear latch attaching screws. 8. Separate the rear latch from the inner door panel. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > Customer Interest for Sliding Door Latch: > 23-15-00 > Apr > 00 > Sliding Door - Will Not Open And/Or Close/Latch > Page 6302 9. Inspect the rear latch torsional spring to ensure that it is properly positioned. If the rear latch torsional spring is NOT positioned as shown in Figure 7, perform the Repair Procedure. If the spring is properly positioned and the latch rod clips were attached (Step 5), this bulletin will not correct a door that will not close/latch complaint. Further diagnosis is required. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH IDAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the rear latch assembly (if not already performed). Refer to the 2000 Ram Van/Wagon Service Manual (Publication No.81-370-0007), page 23-42 "Sliding Cargo Door Rear latch Removal." 2. Remove the sliding door inside handle attaching screw (Figure 2) (if not already performed). 3. Remove the inside sliding door handle and spacers (if not already performed). 4. Remove the lock knob from the knob latch rod (if not already performed). 5. Remove the latch cover screws from the door panel (if not already performed). 6. Remove the cover from the door panel (if not already performed). 7. Remove the front latch-to-rear latch control rods from the front latch assembly. 8. Remove the latch rods from the inner door panel. 9. Using a grinder, grind down the rear latch reinforcement trim edge so that the reinforcement is flush with the inner door panel rear latch opening. 10. To prevent corrosion, apply a brushable primer to the exposed bare metal. 11. Connect the latch rods p/n 55076381AB and p/n 55346503AB to the front latch. 12. Position the rear latch p/n 55347099AC near the rear latch opening. 13. Attach the latch rods to the rear latch. 14. Install the latch screws in the door inner panel. Tighten the screws to 11 N.m (95 in. lbs). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > Customer Interest for Sliding Door Latch: > 23-15-00 > Apr > 00 > Sliding Door - Will Not Open And/Or Close/Latch > Page 6303 15. Position the front latch cover onto the inner door panel with the knob latch rod and the outside handle shaft inserted in the cover holes. 16. Install the cover screws in the door panel. 17. Position the inside door handle spacers and the inside handle onto the outside handle shaft. Verify both spacers are installed. 18. Attach the inside handle with the screw. 19. Install lock knob. 20. Position the door trim panel on the door inner panel and press inward around the edge of the panel. 21. Position the door pull handle onto the trim panel with the screw holes aligned. 22. Install the pull handle screws. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8- New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > 23-15-00 > Apr > 00 > Sliding Door - Will Not Open And/Or Close/Latch Sliding Door Latch: All Technical Service Bulletins Sliding Door - Will Not Open And/Or Close/Latch NUMBER: 23-15-00 GROUP: Body DATE: April 21, 2000 SUBJECT: Sliding Door Will Not Open And/Or Close/Latch MODELS: 1998 - 2000 (AB) Ram Van/Wagon OVERVIEW: This bulletin involves installing revised sliding door rear latch assembly and latch rods and modifying the rear latch opening. NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE SLIDING SIDE DOOR (SALES CODE GKF) BUILT BEFORE FEBRUARY 26,2000 (MDH 0226XX). SYMPTOM/CONDITION: The sliding door will not open and/or will not close/latch. DIAGNOSIS: DOOR WILL NOT OPEN 1. Remove the sliding door trim panel attaching screws. 2. Remove the door pull handle (Figure 1). 3. Using a trim removal tool, carefully pry the trim panel away from the door inner panel. 4. Separate the trim panel from the sliding door. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > 23-15-00 > Apr > 00 > Sliding Door - Will Not Open And/Or Close/Latch > Page 6309 5. Remove the sliding door inside handle attaching screw (Figure 2). 6. Remove the inside sliding door handle and spacers. 7. Remove the lock knob from the knob latch rod. 8. Remove the latch cover screws from the door panel. 9. Remove the cover from the door panel. 10. Inspect the front latch-to-rear latch control rod. If the rod is positioned as shown in Figure 3, the rear latch has over-traveled and jammed. Use a screwdriver to pry the latch rod rearward to dislodge the latch rod. A dislodged rod can be identified by the rod being free to move fore and aft by grasping the rod with your hand. If the rod is not positioned as shown in Figure 3, this bulletin will not correct a door that will not open complaint. Further diagnosis is required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > 23-15-00 > Apr > 00 > Sliding Door - Will Not Open And/Or Close/Latch > Page 6310 11. Remove the rear door latch attaching screws (Figure 4). 12. With the rear latch loose, push open the rear of the door enough to disconnect the rear latch rods (Figure 5). 13. Remove the rear latch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > 23-15-00 > Apr > 00 > Sliding Door - Will Not Open And/Or Close/Latch > Page 6311 14. Inspect the rear latch reinforcement on the rear latch opening of the inner door panel for a high trim condition as shown in Figure 6. If the reinforcement sticks up higher than the opening, perform the Repair Procedure. If the rod is not positioned as shown in Figure 3 and/or the latch reinforcement does not stick up higher than the opening, this bulletin will not correct a door that will not open complaint. Further diagnosis is required. DOOR WILL NOT CLOSE/LATCH 1. Remove the sliding door trim panel attaching screws. 2. Remove the door pull handle (Figure 1). 3. Using a trim removal tool, carefully pry the trim panel away from the door inner panel. 4. Separate the trim panel from the sliding door. 5. Inspect the front latch-to-rear latch control rod to ensure that the rod clips are attached. Perform the Repair Procedure if the rod clips are not attached. 6. Disconnect both front latch-to-rear latch control rods. 7. Remove the rear latch attaching screws. 8. Separate the rear latch from the inner door panel. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > 23-15-00 > Apr > 00 > Sliding Door - Will Not Open And/Or Close/Latch > Page 6312 9. Inspect the rear latch torsional spring to ensure that it is properly positioned. If the rear latch torsional spring is NOT positioned as shown in Figure 7, perform the Repair Procedure. If the spring is properly positioned and the latch rod clips were attached (Step 5), this bulletin will not correct a door that will not close/latch complaint. Further diagnosis is required. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH IDAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the rear latch assembly (if not already performed). Refer to the 2000 Ram Van/Wagon Service Manual (Publication No.81-370-0007), page 23-42 "Sliding Cargo Door Rear latch Removal." 2. Remove the sliding door inside handle attaching screw (Figure 2) (if not already performed). 3. Remove the inside sliding door handle and spacers (if not already performed). 4. Remove the lock knob from the knob latch rod (if not already performed). 5. Remove the latch cover screws from the door panel (if not already performed). 6. Remove the cover from the door panel (if not already performed). 7. Remove the front latch-to-rear latch control rods from the front latch assembly. 8. Remove the latch rods from the inner door panel. 9. Using a grinder, grind down the rear latch reinforcement trim edge so that the reinforcement is flush with the inner door panel rear latch opening. 10. To prevent corrosion, apply a brushable primer to the exposed bare metal. 11. Connect the latch rods p/n 55076381AB and p/n 55346503AB to the front latch. 12. Position the rear latch p/n 55347099AC near the rear latch opening. 13. Attach the latch rods to the rear latch. 14. Install the latch screws in the door inner panel. Tighten the screws to 11 N.m (95 in. lbs). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > 23-15-00 > Apr > 00 > Sliding Door - Will Not Open And/Or Close/Latch > Page 6313 15. Position the front latch cover onto the inner door panel with the knob latch rod and the outside handle shaft inserted in the cover holes. 16. Install the cover screws in the door panel. 17. Position the inside door handle spacers and the inside handle onto the outside handle shaft. Verify both spacers are installed. 18. Attach the inside handle with the screw. 19. Install lock knob. 20. Position the door trim panel on the door inner panel and press inward around the edge of the panel. 21. Position the door pull handle onto the trim panel with the screw holes aligned. 22. Install the pull handle screws. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8- New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > Page 6314 Sliding Door Latch: By Symptom Technical Service Bulletin # 23-15-00 Date: 000421 Sliding Door - Will Not Open And/Or Close/Latch NUMBER: 23-15-00 GROUP: Body DATE: April 21, 2000 SUBJECT: Sliding Door Will Not Open And/Or Close/Latch MODELS: 1998 - 2000 (AB) Ram Van/Wagon OVERVIEW: This bulletin involves installing revised sliding door rear latch assembly and latch rods and modifying the rear latch opening. NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE SLIDING SIDE DOOR (SALES CODE GKF) BUILT BEFORE FEBRUARY 26,2000 (MDH 0226XX). SYMPTOM/CONDITION: The sliding door will not open and/or will not close/latch. DIAGNOSIS: DOOR WILL NOT OPEN 1. Remove the sliding door trim panel attaching screws. 2. Remove the door pull handle (Figure 1). 3. Using a trim removal tool, carefully pry the trim panel away from the door inner panel. 4. Separate the trim panel from the sliding door. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > Page 6315 5. Remove the sliding door inside handle attaching screw (Figure 2). 6. Remove the inside sliding door handle and spacers. 7. Remove the lock knob from the knob latch rod. 8. Remove the latch cover screws from the door panel. 9. Remove the cover from the door panel. 10. Inspect the front latch-to-rear latch control rod. If the rod is positioned as shown in Figure 3, the rear latch has over-traveled and jammed. Use a screwdriver to pry the latch rod rearward to dislodge the latch rod. A dislodged rod can be identified by the rod being free to move fore and aft by grasping the rod with your hand. If the rod is not positioned as shown in Figure 3, this bulletin will not correct a door that will not open complaint. Further diagnosis is required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > Page 6316 11. Remove the rear door latch attaching screws (Figure 4). 12. With the rear latch loose, push open the rear of the door enough to disconnect the rear latch rods (Figure 5). 13. Remove the rear latch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > Page 6317 14. Inspect the rear latch reinforcement on the rear latch opening of the inner door panel for a high trim condition as shown in Figure 6. If the reinforcement sticks up higher than the opening, perform the Repair Procedure. If the rod is not positioned as shown in Figure 3 and/or the latch reinforcement does not stick up higher than the opening, this bulletin will not correct a door that will not open complaint. Further diagnosis is required. DOOR WILL NOT CLOSE/LATCH 1. Remove the sliding door trim panel attaching screws. 2. Remove the door pull handle (Figure 1). 3. Using a trim removal tool, carefully pry the trim panel away from the door inner panel. 4. Separate the trim panel from the sliding door. 5. Inspect the front latch-to-rear latch control rod to ensure that the rod clips are attached. Perform the Repair Procedure if the rod clips are not attached. 6. Disconnect both front latch-to-rear latch control rods. 7. Remove the rear latch attaching screws. 8. Separate the rear latch from the inner door panel. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > Page 6318 9. Inspect the rear latch torsional spring to ensure that it is properly positioned. If the rear latch torsional spring is NOT positioned as shown in Figure 7, perform the Repair Procedure. If the spring is properly positioned and the latch rod clips were attached (Step 5), this bulletin will not correct a door that will not close/latch complaint. Further diagnosis is required. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH IDAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the rear latch assembly (if not already performed). Refer to the 2000 Ram Van/Wagon Service Manual (Publication No.81-370-0007), page 23-42 "Sliding Cargo Door Rear latch Removal." 2. Remove the sliding door inside handle attaching screw (Figure 2) (if not already performed). 3. Remove the inside sliding door handle and spacers (if not already performed). 4. Remove the lock knob from the knob latch rod (if not already performed). 5. Remove the latch cover screws from the door panel (if not already performed). 6. Remove the cover from the door panel (if not already performed). 7. Remove the front latch-to-rear latch control rods from the front latch assembly. 8. Remove the latch rods from the inner door panel. 9. Using a grinder, grind down the rear latch reinforcement trim edge so that the reinforcement is flush with the inner door panel rear latch opening. 10. To prevent corrosion, apply a brushable primer to the exposed bare metal. 11. Connect the latch rods p/n 55076381AB and p/n 55346503AB to the front latch. 12. Position the rear latch p/n 55347099AC near the rear latch opening. 13. Attach the latch rods to the rear latch. 14. Install the latch screws in the door inner panel. Tighten the screws to 11 N.m (95 in. lbs). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > Page 6319 15. Position the front latch cover onto the inner door panel with the knob latch rod and the outside handle shaft inserted in the cover holes. 16. Install the cover screws in the door panel. 17. Position the inside door handle spacers and the inside handle onto the outside handle shaft. Verify both spacers are installed. 18. Attach the inside handle with the screw. 19. Install lock knob. 20. Position the door trim panel on the door inner panel and press inward around the edge of the panel. 21. Position the door pull handle onto the trim panel with the screw holes aligned. 22. Install the pull handle screws. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8- New Part Technical Service Bulletin # 23-15-00 Date: 000421 Sliding Door - Will Not Open And/Or Close/Latch NUMBER: 23-15-00 GROUP: Body DATE: April 21, 2000 SUBJECT: Sliding Door Will Not Open And/Or Close/Latch MODELS: 1998 - 2000 (AB) Ram Van/Wagon OVERVIEW: This bulletin involves installing revised sliding door rear latch assembly and latch rods and modifying the rear latch opening. NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE SLIDING SIDE DOOR (SALES CODE GKF) BUILT BEFORE FEBRUARY 26,2000 (MDH 0226XX). SYMPTOM/CONDITION: The sliding door will not open and/or will not close/latch. DIAGNOSIS: DOOR WILL NOT OPEN 1. Remove the sliding door trim panel attaching screws. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > Page 6320 2. Remove the door pull handle (Figure 1). 3. Using a trim removal tool, carefully pry the trim panel away from the door inner panel. 4. Separate the trim panel from the sliding door. 5. Remove the sliding door inside handle attaching screw (Figure 2). 6. Remove the inside sliding door handle and spacers. 7. Remove the lock knob from the knob latch rod. 8. Remove the latch cover screws from the door panel. 9. Remove the cover from the door panel. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > Page 6321 10. Inspect the front latch-to-rear latch control rod. If the rod is positioned as shown in Figure 3, the rear latch has over-traveled and jammed. Use a screwdriver to pry the latch rod rearward to dislodge the latch rod. A dislodged rod can be identified by the rod being free to move fore and aft by grasping the rod with your hand. If the rod is not positioned as shown in Figure 3, this bulletin will not correct a door that will not open complaint. Further diagnosis is required. 11. Remove the rear door latch attaching screws (Figure 4). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > Page 6322 12. With the rear latch loose, push open the rear of the door enough to disconnect the rear latch rods (Figure 5). 13. Remove the rear latch. 14. Inspect the rear latch reinforcement on the rear latch opening of the inner door panel for a high trim condition as shown in Figure 6. If the reinforcement sticks up higher than the opening, perform the Repair Procedure. If the rod is not positioned as shown in Figure 3 and/or the latch reinforcement does not stick up higher than the opening, this bulletin will not correct a door that will not open complaint. Further diagnosis is required. DOOR WILL NOT CLOSE/LATCH 1. Remove the sliding door trim panel attaching screws. 2. Remove the door pull handle (Figure 1). 3. Using a trim removal tool, carefully pry the trim panel away from the door inner panel. 4. Separate the trim panel from the sliding door. 5. Inspect the front latch-to-rear latch control rod to ensure that the rod clips are attached. Perform the Repair Procedure if the rod clips are not attached. 6. Disconnect both front latch-to-rear latch control rods. 7. Remove the rear latch attaching screws. 8. Separate the rear latch from the inner door panel. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > Page 6323 9. Inspect the rear latch torsional spring to ensure that it is properly positioned. If the rear latch torsional spring is NOT positioned as shown in Figure 7, perform the Repair Procedure. If the spring is properly positioned and the latch rod clips were attached (Step 5), this bulletin will not correct a door that will not close/latch complaint. Further diagnosis is required. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH IDAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the rear latch assembly (if not already performed). Refer to the 2000 Ram Van/Wagon Service Manual (Publication No.81-370-0007), page 23-42 "Sliding Cargo Door Rear latch Removal." 2. Remove the sliding door inside handle attaching screw (Figure 2) (if not already performed). 3. Remove the inside sliding door handle and spacers (if not already performed). 4. Remove the lock knob from the knob latch rod (if not already performed). 5. Remove the latch cover screws from the door panel (if not already performed). 6. Remove the cover from the door panel (if not already performed). 7. Remove the front latch-to-rear latch control rods from the front latch assembly. 8. Remove the latch rods from the inner door panel. 9. Using a grinder, grind down the rear latch reinforcement trim edge so that the reinforcement is flush with the inner door panel rear latch opening. 10. To prevent corrosion, apply a brushable primer to the exposed bare metal. 11. Connect the latch rods p/n 55076381AB and p/n 55346503AB to the front latch. 12. Position the rear latch p/n 55347099AC near the rear latch opening. 13. Attach the latch rods to the rear latch. 14. Install the latch screws in the door inner panel. Tighten the screws to 11 N.m (95 in. lbs). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > Page 6324 15. Position the front latch cover onto the inner door panel with the knob latch rod and the outside handle shaft inserted in the cover holes. 16. Install the cover screws in the door panel. 17. Position the inside door handle spacers and the inside handle onto the outside handle shaft. Verify both spacers are installed. 18. Attach the inside handle with the screw. 19. Install lock knob. 20. Position the door trim panel on the door inner panel and press inward around the edge of the panel. 21. Position the door pull handle onto the trim panel with the screw holes aligned. 22. Install the pull handle screws. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8- New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Handle: > 23-40-98 > Sep > 98 > Side/Rear Cargo Door - Outside Handle(s) Loose Trunk / Liftgate Handle: Customer Interest Side/Rear Cargo Door - Outside Handle(s) Loose NO: 23-40-98 GROUP: Body DATE: Sep. 4, 1998 SUBJECT: Side And/Or Rear Cargo Door Outside Handle(s) Loose MODELS: 1998 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE MAY 16, 1998 (MDH 0516XX). SYMPTOM/CONDITION: Side and/or rear cargo door outside handle(s) are loose. DIAGNOSIS: Inspect the side and rear cargo door handles to verify handle looseness. If either the side and/or rear cargo door handle(s) is/are loose, perform the Repair Procedure. PARTS REQUIRED: AR (1) 04318031 Adhesive, Lock & Seal AR (1) 55075654 Handle, Dual Cargo Door AR (1) 55359037AA Handle, Single Rear Cargo Door AR (1) J4200306 Nut, Door Handle Retaining REPAIR PROCEDURE: This bulletin involves adding Mopar Lock & Seal Adhesive to the threads of the door handle stud and nut. 1. Open the cargo door(s). 2. Remove the inside door handle retaining screw and separate the handle from the vehicle. 3. Remove the inside door handle trim bezel. This can be accomplished by inserting trim sticks in the upper half of the trim bezel. Then, gently tapping on the upper bezel half with a plastic mallet until it is released from the trim bezel. Remove the upper bezel from the trim and then tap the lower trim bezel upward. 4. Use a trim removal tool to pry the trim panel away from the door inner panel. 5. Separate the trim panel away from the door. 6. Remove the nuts that attach the outside door handle to the door panel. 7. Apply a small amount of Mopar Lock & Seal p/n 04318031 to the threads of the nuts. Then, install the nuts onto the outside door handle. Tighten the nuts to 2.8 Nm (25 in.lbs.). NOTE: IF THE STUDS ON THE OUTSIDE DOOR HANDLE ARE BROKEN, REPLACE THE DOOR HANDLE AND ATTACHING NUTS (SEE PARTS REQUIRED SECTION). USE MOPAR LOCK & SEAL PIN 04318031 ON THE THREADS OF THE NUTS WHEN INSTALLING THE HANDLE. REFER TO THE 1998 RAM VAN SERVICE MANUAL (PUBLICATION NO.81-370-8107), PAGE 23-44 FOR DUAL CARGO DOOR OUTSIDE HANDLE REMOVAL AND INSTALLATION PROCEDURES OR PAGES 23-49 AND 23-50 FOR A SINGLE REAR CARGO DOOR OUTSIDE HANDLE REMOVAL AND INSTALLATION PROCEDURES. 8. Position the trim panel onto the inner door panel. 9. Push inward and force the clip retainers into the door panel holes. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Handle: > 23-40-98 > Sep > 98 > Side/Rear Cargo Door - Outside Handle(s) Loose > Page 6334 10. Insert the lower trim bezel half into the door handle opening and seat it in place. 11. Insert the upper bezel half into the door handle opening and seat it in place. 12. Install the inside door handle. Tighten the screw to 11 Nm (95 in.lbs.). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-42-15-97 Apply Adhesive To The Outside Cargo Door Handle Nut Threads - One 0.2 Hrs. 23-42-15-98 Remove And Install Outside Cargo Door Handle And Apply Adhesive To The Outside Cargo Door Handle Nut Threads One 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Handle: > 23-40-98 > Sep > 98 > Side/Rear Cargo Door - Outside Handle(s) Loose Trunk / Liftgate Handle: All Technical Service Bulletins Side/Rear Cargo Door - Outside Handle(s) Loose NO: 23-40-98 GROUP: Body DATE: Sep. 4, 1998 SUBJECT: Side And/Or Rear Cargo Door Outside Handle(s) Loose MODELS: 1998 (AB) Ram Van/Wagon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE MAY 16, 1998 (MDH 0516XX). SYMPTOM/CONDITION: Side and/or rear cargo door outside handle(s) are loose. DIAGNOSIS: Inspect the side and rear cargo door handles to verify handle looseness. If either the side and/or rear cargo door handle(s) is/are loose, perform the Repair Procedure. PARTS REQUIRED: AR (1) 04318031 Adhesive, Lock & Seal AR (1) 55075654 Handle, Dual Cargo Door AR (1) 55359037AA Handle, Single Rear Cargo Door AR (1) J4200306 Nut, Door Handle Retaining REPAIR PROCEDURE: This bulletin involves adding Mopar Lock & Seal Adhesive to the threads of the door handle stud and nut. 1. Open the cargo door(s). 2. Remove the inside door handle retaining screw and separate the handle from the vehicle. 3. Remove the inside door handle trim bezel. This can be accomplished by inserting trim sticks in the upper half of the trim bezel. Then, gently tapping on the upper bezel half with a plastic mallet until it is released from the trim bezel. Remove the upper bezel from the trim and then tap the lower trim bezel upward. 4. Use a trim removal tool to pry the trim panel away from the door inner panel. 5. Separate the trim panel away from the door. 6. Remove the nuts that attach the outside door handle to the door panel. 7. Apply a small amount of Mopar Lock & Seal p/n 04318031 to the threads of the nuts. Then, install the nuts onto the outside door handle. Tighten the nuts to 2.8 Nm (25 in.lbs.). NOTE: IF THE STUDS ON THE OUTSIDE DOOR HANDLE ARE BROKEN, REPLACE THE DOOR HANDLE AND ATTACHING NUTS (SEE PARTS REQUIRED SECTION). USE MOPAR LOCK & SEAL PIN 04318031 ON THE THREADS OF THE NUTS WHEN INSTALLING THE HANDLE. REFER TO THE 1998 RAM VAN SERVICE MANUAL (PUBLICATION NO.81-370-8107), PAGE 23-44 FOR DUAL CARGO DOOR OUTSIDE HANDLE REMOVAL AND INSTALLATION PROCEDURES OR PAGES 23-49 AND 23-50 FOR A SINGLE REAR CARGO DOOR OUTSIDE HANDLE REMOVAL AND INSTALLATION PROCEDURES. 8. Position the trim panel onto the inner door panel. 9. Push inward and force the clip retainers into the door panel holes. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Handle: > 23-40-98 > Sep > 98 > Side/Rear Cargo Door - Outside Handle(s) Loose > Page 6340 10. Insert the lower trim bezel half into the door handle opening and seat it in place. 11. Insert the upper bezel half into the door handle opening and seat it in place. 12. Install the inside door handle. Tighten the screw to 11 Nm (95 in.lbs.). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-42-15-97 Apply Adhesive To The Outside Cargo Door Handle Nut Threads - One 0.2 Hrs. 23-42-15-98 Remove And Install Outside Cargo Door Handle And Apply Adhesive To The Outside Cargo Door Handle Nut Threads One 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: The airbag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the airbag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the airbag and possible personal injury. The fasteners, screws, and bolts, originally used for the airbag components, have special coatings and are specifically designed for the airbag system. They must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books . Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6346 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box Replacement/Rolldown Glove Compartment: Service and Repair Glove Box Replacement/Rolldown The glove box on this model can be rolled down beyond the integral stops in order to access many components for service, without complete glove box removal. See Roll Down for the procedure. The glove box can also be removed from the instrument panel completely See Removal for the procedure. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Roll Down 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Locate the two rubber stop bumpers on the sides of the instrument panel glove box opening. Glove Box Roll Down 4. Depress both sides of the glove box bin inwards far enough so that the glove box stops that are integral to each side of the bin can be moved past the rubber stop bumpers. 5. Holding the sides of the glove box bin depressed, roll the glove box downward until the stops molded into the sides of the glove box bin are beyond the rubber stop bumpers, then release the sides of the glove box bin. 6. Reverse the roll down procedure to roll the glove box back up. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Roll down the glove box. See Glove Box - Roll Down Procedures. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box Replacement/Rolldown > Page 6351 Glove Box Remove/Install 3. Remove the three screws that secure the glove box hinge to the instrument panel lower glove box opening reinforcement. 4. Remove the glove box from the instrument panel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 3.4 N.m (30 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box Replacement/Rolldown > Page 6352 Glove Compartment: Service and Repair Glove Box Component Replacement The glove box bin and inner door unit and the glove box handle and latch unit are available for service. The glove box outer door and the glove box hinge are serviced only in the complete glove box assembly. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Handle And Latch 1. Disconnect and isolate the battery negative cable. 2. Roll down the glove box from the instrument panel. See Glove Box - Roll Down replacement. Glove Box Latch And Handle Remove/Install 3. Remove the four screws that secure the handle and latch unit to the glove box inner door. 4. Remove the handle and latch unit from the glove box inner door. 5. Reverse the removal procedures to install. Tighten the mounting screws to 1.9 N.m (17 in. lbs.). Inner Door And Bin 1. Disconnect and isolate the battery negative cable. 2. Remove the handle and latch from the glove box. See Glove Box Components - Handle and Latch Replacement for the procedures. 3. Remove the glove box from the instrument panel. See Glove Box - Removal Replacement. Glove Box Inner Door And Bin Remove/Install 4. Remove the two screws that secure the bottom of the glove box outer door to the bottom of the glove box bin. 5. Remove the eight screws that secure the inner door and bin unit to the glove box outer door. 6. Separate the inner door and bin unit from the glove box outer door. 7. Reverse the removal procedures to install. Tighten the mounting screws to 1.9 N.m (17 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair Trim Panel: Service and Repair WINDSHIELD HEADER, A-PILLAR AND FRONT DOOR HEADER TRIM PANELS REMOVAL 1. Remove the sunvisor and retaining clip screws from the windshield header. Remove the visors and clips from the windshield header. 2. Remove the trim panel screws from the body interior panels. 3. Remove the trim panels from the body interior panels. INSTALLATION 1. Position the trim panels at the body interior panels. 2. Install the trim panel screws in the body interior panels. Tighten the screws to 2 Nm (17 in. lbs.) torque. 3. Position the sunvisors and retaining clips on the windshield header with the screw holes aligned. 4. Install the screws in the windshield header. Tighten the screws to 2 Nm (17 in. lbs.) torque. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair A power lock and Remote Keyless Entry (RKE) module is only used on high-line versions of this vehicle that are not equipped with the optional Vehicle Theft Security System (VTSS). Models equipped with the optional VTSS have the power lock and RKE functions controlled by the Central Timer Module (CTM). See Power Lock System and Remote Keyless Entry System in the General Information for more information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the engine cover from the passenger compartment. Power Lock And Remote Keyless Entry Module Remove/Install 3. Remove the two screws that secure the power lock and RKE module to the inboard side of the left center instrument panel support. 4. Pull the power lock and RKE module away from its mounting location far enough to access and unplug the two wire harness connectors. 5. Remove the power lock and RKE module from the instrument panel. 6. Reverse the removal procedures to install. Tighten the mounting screws to 3.3 N.m (30 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Programming Connector > Component Information > Locations 16-Way Data Link Connector - Typical Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Description and Operation Keyless Entry Receiver: Description and Operation SYSTEM OPERATION The Remote Keyless Entry (RKE) receiver is a radio frequency unit that is integral to the power lock and RKE module or to the Central Timer Module (CTM). The RKE receiver has a memory function to retain the vehicle access codes of the RKE transmitters, even if the battery is disconnected. The power lock and RKE module can store two transmitter vehicle access codes, the CTM can store up to four. The RKE receiver is energized by one of two radio frequency inputs from the RKE transmitter, Unlock or Lock. The programming of the power lock and RKE module or the CTM responds to these RKE inputs, as well as many other inputs, by sending the proper control outputs to the power lock motors, the courtesy lamp circuit, and (with the CTM-based RKE system only) the horn relay. The RKE receiver is only serviced as a unit with the power lock and RKE module or the CTM and, if faulty or damaged, the module unit must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure Keyless Entry Transmitter Battery: Customer Interest RKE Transmitter - Premature Battery Failure NO: 08-39-97 GROUP: Electrical DATE: Nov. 28, 1997 SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely MODELS: 1997 - 1998 (AB) Ram Van/Wagon 1997 - 1998 (AN) Dakota/Dakota Cab & Chassis 1998 (BRIBE)Ram Truck 1998 (DN) Durango 1997 (LH) Concorde/Intrepid/LHS/Vision 1997 - 1998 (NS) Town & Country/Caravan/Voyager 1997 - 1998 (PL) Neon 1997 (PR) Prowler 1997 - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX). SYMPTOM/CONDITION: Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH 0815XX, perform the Repair Procedure. PARTS REQUIRED: AR 04686366 Transmitter, RKE- NS, PL & PR AR 04759136AB Transmitter, RKE- LH AR 56007049 Transmitter, RKE- AB & 1997 AN AR 56008761 Transmitter 1, RKE- ZJ & DN AR 56008762 Transmitter 2, RKE- ZJ AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitter(s). 1. Replace RKE transmitter(s) that have discharged batteries. 2. Program the RKE transmitter(s) to the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-28-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure Keyless Entry Transmitter Battery: All Technical Service Bulletins RKE Transmitter - Premature Battery Failure NO: 08-39-97 GROUP: Electrical DATE: Nov. 28, 1997 SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely MODELS: 1997 - 1998 (AB) Ram Van/Wagon 1997 - 1998 (AN) Dakota/Dakota Cab & Chassis 1998 (BRIBE)Ram Truck 1998 (DN) Durango 1997 (LH) Concorde/Intrepid/LHS/Vision 1997 - 1998 (NS) Town & Country/Caravan/Voyager 1997 - 1998 (PL) Neon 1997 (PR) Prowler 1997 - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX). SYMPTOM/CONDITION: Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH 0815XX, perform the Repair Procedure. PARTS REQUIRED: AR 04686366 Transmitter, RKE- NS, PL & PR AR 04759136AB Transmitter, RKE- LH AR 56007049 Transmitter, RKE- AB & 1997 AN AR 56008761 Transmitter 1, RKE- ZJ & DN AR 56008762 Transmitter 2, RKE- ZJ AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitter(s). 1. Replace RKE transmitter(s) that have discharged batteries. 2. Program the RKE transmitter(s) to the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-28-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > Page 6381 Keyless Entry Transmitter Battery: Service and Repair The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry at the center seam of the transmitter case halves near the key ring until the two halves unsnap. 2. Lift the back half of the transmitter case off of the transmitter. 3. Remove the two batteries from the transmitter. 4. Replace the two batteries with new Duracell DL2016, or their equivalent. Be certain that the batteries are installed with their polarity correctly oriented. 5. Align the two transmitter case halves with each other, and squeeze them firmly together until they snap back into place. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams Door Lock Motor Connectors Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 6386 Power Door Lock Actuator: Description and Operation SYSTEM OPERATION In the power lock and Remote Keyless Entry (RKE) systems, the door latch lock mechanisms can be actuated by a reversible electric motor. A power lock motor module is secured to the bottom of the door latch mounted within each front door. A power lock motor is integral to the latches used on dual side or rear doors. A separate power lock motor with a connecting link is used to actuate the latch in the sliding side or single rear door. The power lock motor direction is controlled by the battery and ground feeds from the power lock and unlock relays. The power lock and unlock relays are integral to the power lock and Remote Keyless Entry (RKE) module, or the Central Timer Module (CTM). The power door lock motors cannot be repaired and, if faulty or damaged, they must be replaced. On dual side or rear doors the entire door latch unit must be replaced. The front door, sliding side door, and single rear door power lock motors are serviced separately. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 6387 Power Door Lock Actuator: Testing and Inspection Before you proceed with this diagnosis, confirm proper power lock switch, power lock and Remote Keyless Entry (RKE) module or Central Timer Module (CTM), and power lock switch output circuit operation. See Power Lock Switch, and Power Lock and Remote Keyless Entry Module or Central Timer Module in the Diagnosis. Remember, the module circuitry controls the output to each of the power lock motors. 1. Check each power lock motor for correct operation while moving the power lock switch to both the Lock and Unlock positions. If all of the power lock motors are inoperative, go to Step 3. If one power lock motor is inoperative, go to Step 4. 2. If all of the power lock motors are inoperative, the problem may be caused by one shorted motor. Unplugging a shorted power lock motor from the power lock circuit will allow the good power lock motors to operate. Unplug each power lock motor wire harness connector, one at a time, and recheck both the lock and unlock functions by operating the power lock switch. If all of the power lock motors are still inoperative after the above test, check for a short or open circuit between the power lock motors and the power lock and RKE module or the CTM. If unplugging one power lock motor causes the other motor to become functional, go to Step 4 to test the unplugged motor. 3. Once it is determined which power lock motor is inoperative, that motor can be tested as follows. Unplug the wire harness connector at the inoperative power lock motor. Apply 12 volts to the motor terminals to check its operation in one direction. Reverse the polarity to check the operation in the other direction. If OK, repair the short or open circuits between the power lock motor and the power lock and RKE module or the CTM as required. If not OK, replace the faulty power lock motor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 6388 Power Door Lock Actuator: Service and Repair REMOVAL Front Door 1. Disconnect and isolate the battery negative cable. 2. Remove the door latch assembly from the front door. Front Door Power Lock Motor Remove/Install 3. Remove the screw that secures the power lock motor to the front door latch. 4. Pivot the side of the power lock motor from which the screw was removed downwards to remove it from the bottom of the front door latch. 5. Reverse the removal procedures to install. Tighten the mounting screw to 2.2 N.m (20 in. lbs.). Dual Side/Rear Door On models equipped with dual side or rear doors the power lock motor is integral to the door latch unit. If the power lock motor is faulty or damaged, the entire door latch unit must be replaced. Sliding Side Or Single Rear Door 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the door. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 6389 Sliding Side Door Power Lock Motor Remove/Install Single Rear Door Lock Motor Remove/Install 3. Reach through the access hole in the inner door panel to disengage the connecting link from the power lock motor. 4. Disengage the power lock motor wire harness connector retainer from its mounting hole and unplug the connector. 5. Remove the screws that secure the power lock motor mounting bracket to the inner door panel. 6. Remove the power lock motor from the door. 7. Reverse the removal procedures to install. Tighten the mounting screws to 10 N.m (90 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Testing and Inspection Power Door Lock Control Module: Testing and Inspection The power lock and Remote Keyless Entry (RKE) module is used on models that are not equipped with the optional Vehicle Theft Security System (VTSS). 1. Check the fused B(+) fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Check the fused ignition switch output fuse in the junction block. If OK, go to Step 5. If not OK, rep air the shorted circuit or component as required and replace the faulty fuse. 4. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output fuse in the junction block. If OK, turn the ignition switch to the Off position and go to Step 6. If not OK, repair the open circuit to the ignition switch as required. 5. Disconnect and isolate the battery negative cable. Access and unplug the power lock and RKE module wire harness connectors. See Power Lock and Remote Keyless Entry Module in the Removal and Installation for the procedures. 6. Check the wire harness connectors and the receptacles in the power lock and RKE module for loose, corroded, or damaged terminals and pins. If OK, go to Step 8. If not OK, repair the connections as required. 7. Probe the ground circuit cavity in the black power lock and RKE module wire harness connector and check for continuity to a good ground. There should be continuity. If OK, go to Step 9. If not OK, repair the open circuit to ground as required. 8. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity in the black power lock and RKE module wire harness connector. If OK, go to Step 10. If not OK, repair the open circuit to the fuse in the junction block as required. 9. Probe the door lock switch output (lock) circuit cavity in the black power lock and RKE module wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 11. If not OK, repair the open circuit from either or both power lock switch(s) to the power lock and RKE module as required. 10. Probe the door lock switch output (unlock) circuit cavity in the black power lock and RKE module wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 12. If not OK, repair the open circuit from either or both power lock switch(s) to the power lock and RKE module as required. 11. Check for continuity between the door jamb switch sense circuit cavity of the black power lock and RKE module wire harness connector and a good ground. There should be no continuity with both the side and the rear cargo doors closed, and there should be continuity with any of the side or rear cargo doors opened. Test each of the side and the rear doors. If OK, go to Step 13. If not OK, repair the open circuit to the door jamb switch(s) or replace the faulty door jamb switch(s) as required. 12. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity in the blue power lock and RKE module wire harness connector. If OK, turn the ignition switch to the Off position and go to Step 14. If not OK, repair the open circuit to the fuse in the junction block as required. 13. Plug the wire harness connectors back into the power lock and RKE module. Back probe the door latch switch sense circuit cavity of the black power lock and RKE module wire harness connector and check for continuity to a good ground. There should be no continuity. Press and release the Unlock button of the RKE transmitter. There should now be continuity for about thirty seconds. If OK, go to Step 15. If not OK, replace the faulty power lock and RKE module. 14. Back probe the door lock driver circuit cavity in the black power lock and RKE module wire harness connector and check for battery voltage as the power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the RKE transmitter. If OK, go to Step 16. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty power lock and RKE module. 15. Still back probing the door lock driver circuit cavity in the black power lock and RKE module wire harness connector, open the side or rear cargo door. Move the power lock switch to the Lock position or press the Lock button of the RKE transmitter. Now close all of the doors. Within five seconds of the last door closing, there should be battery voltage on the door lock driver circuit. If OK, go to Step 17. If not OK, replace the faulty power lock and RKE module. 16. Back probe the door unlock driver circuit cavity in the black power lock and RKE module wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter. If OK, see Power Lock Motor in the Diagnosis and Testing. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty power lock and RKE module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Testing and Inspection > Page 6393 Power Door Lock Control Module: Service and Repair A power lock and Remote Keyless Entry (RKE) module is only used on high-line versions of this vehicle that are not equipped with the optional Vehicle Theft Security System (VTSS). Models equipped with the optional VTSS have the power lock and RKE functions controlled by the Central Timer Module (CTM). See Power Lock System and Remote Keyless Entry System in the General Information for more information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the engine cover from the passenger compartment. Power Lock And Remote Keyless Entry Module Remove/Install 3. Remove the two screws that secure the power lock and RKE module to the inboard side of the left center instrument panel support. 4. Pull the power lock and RKE module away from its mounting location far enough to access and unplug the two wire harness connectors. 5. Remove the power lock and RKE module from the instrument panel. 6. Reverse the removal procedures to install. Tighten the mounting screws to 3.3 N.m (30 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6397 Power Door Lock Switch: Description and Operation SYSTEM OPERATION The power locks can be controlled by a two-way switch mounted in a bezel on the mirror flag bezel trim of each front door. The power lock switch controls the battery feeds to the lock and unlock sense inputs of the power lock and Remote Keyless Entry (RKE) module or the Central Timer Module (CTM). The relays that are integral to the power lock and REE module or the CTM then direct the correct battery and ground feeds to the power lock motors. The power lock switches cannot be repaired and, if faulty or damaged, the switches must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6398 Power Door Lock Switch: Testing and Inspection 1. Check the fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the power lock switch. 4. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power lock switch wire harness connector. If OK, go to Step 6. If not OK, repair the open circuit to the junction block as required. Power Lock Switch Continuity 5. Test the power lock switch continuity See the Power Lock Switch Continuity chart to determine if the continuity is correct in the Of,, Lock and Unlock switch positions. If OK, repair the door lock switch output (lock and/or unlock) circuit(s) from the power lock switch wire harness connector to the power lock and Remote Keyless Entry (RKE) module or to the Central Timer Module (CTM) as required. If not OK, replace the faulty switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6399 Power Door Lock Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the mirror flag bezel from the inside of the front door. Power Lock Switch Remove/Install 3. From the back side of the mirror flag bezel, remove the screws that secure the power window and power lock switch and mounting plate unit to the mirror flag bezel. 4. Remove the power window and power lock switch and mounting plate unit from the mirror flag bezel. 5. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power lock switch receptacle on the back of the switch mounting plate and pull the switch out of the receptacle. 6. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the switch mounting plate are fully engaged. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation SYSTEM OPERATION Power Mirror Switch Both the right and left power outside mirrors are controlled by a single multi-function switch unit located on and mounted to the upper flag area of the driver side door trim panel. The switch knob is rotated clockwise (right mirror control), or counterclockwise (left mirror control) to select the mirror to be adjusted. The switch knob is then moved in a joystick fashion to control movement of the selected mirror up, down, right, or left. The power mirror switch cannot be repaired and, if faulty or damaged, it must be replaced. The power mirror switch knob is available for service replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation > Page 6404 Power Mirror Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Mirror Switch Knob Remove/Install 2. Pull the power mirror switch control knob rearward to remove it from the switch stem. Power Mirror Switch Nut 3. Remove the nut that secures the power mirror switch to the driver side door trim pane). 4. Remove the mirror flag bezel from the inside of the front door. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation > Page 6405 Power Mirror Switch Remove/Install 5. Unplug the power mirror switch wire harness connector. 6. Remove the power mirror switch from the back of the door mirror flag bezel. 7. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair A power lock and Remote Keyless Entry (RKE) module is only used on high-line versions of this vehicle that are not equipped with the optional Vehicle Theft Security System (VTSS). Models equipped with the optional VTSS have the power lock and RKE functions controlled by the Central Timer Module (CTM). See Power Lock System and Remote Keyless Entry System in the General Information for more information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the engine cover from the passenger compartment. Power Lock And Remote Keyless Entry Module Remove/Install 3. Remove the two screws that secure the power lock and RKE module to the inboard side of the left center instrument panel support. 4. Pull the power lock and RKE module away from its mounting location far enough to access and unplug the two wire harness connectors. 5. Remove the power lock and RKE module from the instrument panel. 6. Reverse the removal procedures to install. Tighten the mounting screws to 3.3 N.m (30 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Testing and Inspection Power Door Lock Control Module: Testing and Inspection The power lock and Remote Keyless Entry (RKE) module is used on models that are not equipped with the optional Vehicle Theft Security System (VTSS). 1. Check the fused B(+) fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Check the fused ignition switch output fuse in the junction block. If OK, go to Step 5. If not OK, rep air the shorted circuit or component as required and replace the faulty fuse. 4. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output fuse in the junction block. If OK, turn the ignition switch to the Off position and go to Step 6. If not OK, repair the open circuit to the ignition switch as required. 5. Disconnect and isolate the battery negative cable. Access and unplug the power lock and RKE module wire harness connectors. See Power Lock and Remote Keyless Entry Module in the Removal and Installation for the procedures. 6. Check the wire harness connectors and the receptacles in the power lock and RKE module for loose, corroded, or damaged terminals and pins. If OK, go to Step 8. If not OK, repair the connections as required. 7. Probe the ground circuit cavity in the black power lock and RKE module wire harness connector and check for continuity to a good ground. There should be continuity. If OK, go to Step 9. If not OK, repair the open circuit to ground as required. 8. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity in the black power lock and RKE module wire harness connector. If OK, go to Step 10. If not OK, repair the open circuit to the fuse in the junction block as required. 9. Probe the door lock switch output (lock) circuit cavity in the black power lock and RKE module wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 11. If not OK, repair the open circuit from either or both power lock switch(s) to the power lock and RKE module as required. 10. Probe the door lock switch output (unlock) circuit cavity in the black power lock and RKE module wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 12. If not OK, repair the open circuit from either or both power lock switch(s) to the power lock and RKE module as required. 11. Check for continuity between the door jamb switch sense circuit cavity of the black power lock and RKE module wire harness connector and a good ground. There should be no continuity with both the side and the rear cargo doors closed, and there should be continuity with any of the side or rear cargo doors opened. Test each of the side and the rear doors. If OK, go to Step 13. If not OK, repair the open circuit to the door jamb switch(s) or replace the faulty door jamb switch(s) as required. 12. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity in the blue power lock and RKE module wire harness connector. If OK, turn the ignition switch to the Off position and go to Step 14. If not OK, repair the open circuit to the fuse in the junction block as required. 13. Plug the wire harness connectors back into the power lock and RKE module. Back probe the door latch switch sense circuit cavity of the black power lock and RKE module wire harness connector and check for continuity to a good ground. There should be no continuity. Press and release the Unlock button of the RKE transmitter. There should now be continuity for about thirty seconds. If OK, go to Step 15. If not OK, replace the faulty power lock and RKE module. 14. Back probe the door lock driver circuit cavity in the black power lock and RKE module wire harness connector and check for battery voltage as the power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the RKE transmitter. If OK, go to Step 16. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty power lock and RKE module. 15. Still back probing the door lock driver circuit cavity in the black power lock and RKE module wire harness connector, open the side or rear cargo door. Move the power lock switch to the Lock position or press the Lock button of the RKE transmitter. Now close all of the doors. Within five seconds of the last door closing, there should be battery voltage on the door lock driver circuit. If OK, go to Step 17. If not OK, replace the faulty power lock and RKE module. 16. Back probe the door unlock driver circuit cavity in the black power lock and RKE module wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter. If OK, see Power Lock Motor in the Diagnosis and Testing. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty power lock and RKE module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Testing and Inspection > Page 6413 Power Door Lock Control Module: Service and Repair A power lock and Remote Keyless Entry (RKE) module is only used on high-line versions of this vehicle that are not equipped with the optional Vehicle Theft Security System (VTSS). Models equipped with the optional VTSS have the power lock and RKE functions controlled by the Central Timer Module (CTM). See Power Lock System and Remote Keyless Entry System in the General Information for more information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the engine cover from the passenger compartment. Power Lock And Remote Keyless Entry Module Remove/Install 3. Remove the two screws that secure the power lock and RKE module to the inboard side of the left center instrument panel support. 4. Pull the power lock and RKE module away from its mounting location far enough to access and unplug the two wire harness connectors. 5. Remove the power lock and RKE module from the instrument panel. 6. Reverse the removal procedures to install. Tighten the mounting screws to 3.3 N.m (30 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6419 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6420 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6421 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6422 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6423 TIME ALLOWANCE: FAILURE CODE: Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Description and Operation Power Seat Motor: Description and Operation SYSTEM OPERATION Power Seat Adjuster And Motors There are three reversible motors that operate the power seat adjuster. The motors are connected to worm-drive gearboxes that move the seat adjuster through a combination of screw-type drive units. The front and rear of a seat are operated by different motors. They can be raised or lowered independently of each other. When the center seat switch is pushed to the Up or Down position, both the front and rear motors operate in unison, moving the entire seat up or down. The forward-rearward motor is operated by pushing the center seat switch to the Forward or Rearward position. When a switch is actuated, a battery feed and a ground path are applied through the switch contacts to the motor(s). The motor(s) and drives operate to move the seat in the selected direction until the switch is released, or until the travel limit of the power seat adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor(s) are reversed through the switch contacts. This causes the motor to run in the opposite direction. Each motor contains a self-resetting circuit breaker to protect it from overload. Consecutive or frequent resetting of the circuit breakers must not be allowed to continue, or the motors may be damaged. Make the necessary repairs. The power seat adjuster and motors cannot be repaired, and are serviced only as a complete unit. If any component in this unit is faulty or damaged, the entire power seat adjuster and motors assembly must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Description and Operation > Page 6427 Power Seat Motor: Testing and Inspection Operate the power seat switch to move all three seat motors in each direction. The seat should move in each of the selected directions. If the power seat adjuster fails to operate in only one direction, move the adjuster a short distance in the opposite direction and test again to be certain that the adjuster is not at its travel limit. If the power seat adjuster still fails to operate in only one direction, see Power Seat Switch in the Diagnosis and Testing. If the power seat adjuster fails to operate in more than one direction, proceed as follows: 1. Test the circuit breaker in the junction block as described. If OK, Step 3. If not OK, replace the faulty circuit breaker. 2. Remove the power seat switch from the seat. Check for battery voltage at the fused B(+) circuit cavity of the power seat switch wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit to the junction block as required. 3. Check for continuity between the ground circuit cavity of the power seat switch wire harness connector and a good ground. There should be continuity If OK, go to Step 5. If not OK, repair the open circuit to ground as required. 4. Test the power seat switch as described. If the switch tests OK, check the wire harness for the inoperative power seat motor(s) between the power seat switch and the motor for shorts or opens. If the circuits check OK, replace the faulty power seat adjuster and motors assembly. If the circuits are not OK, repair the wire harness as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Description and Operation > Page 6428 Power Seat Motor: Service and Repair REMOVAL If the driver side front power seat is in the raised position, it is possible to access and remove the seat and/or the power seat adjuster and motors assembly without removing the seat riser, go to Step 7. If the driver side front power seat is not in the raised position, the seat assembly must be removed from the passenger compartment for service of the power seat adjuster and motors. The seat assembly includes the seat, the seat adjuster and the seat riser. Proceed as follows: 1. Disconnect and isolate the battery negative cable. Seat Riser Rear Shield Remove/Install 2. Remove the four fasteners that secure the lower portion of the rear shield to the seat riser. Power Seat Adjuster And Motors Remove/Install 3. Unplug the power seat adjuster and seat belt switch wire harness connectors. 4. Remove the four nuts that secure the seat riser to the studs on the floor panel. The rear nuts are accessed by lifting up the seat riser rear shield. 5. Remove the seat assembly from the passenger compartment and place it on a suitable work surface for further service. 6. Remove the four screws that secure the power seat adjuster and motors assembly to the bottom of the seat cushion frame. 7. Unplug the wire harness connector between the power seat switch and the power seat adjuster and motors wire harnesses. 8. Remove the seat cushion frame from the power seat adjuster and motors unit. 9. Remove the four nuts that secure the power seat adjuster and motors unit to the seat riser. 10. Remove the power seat adjuster and motors unit from the seat riser. 11. Reverse the removal procedures to install. Tighten the seat mounting hardware as follows: - Seat adjuster to seat cushion frame screws - 22.6 N.m (200 in.lbs.) - Seat adjuster to seat riser nuts - 22.6 N.m (200 in.lbs.) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and Operation Power Seat Switch: Description and Operation SYSTEM OPERATION Power Seat Switch The power seat can be adjusted in six different ways using the power seat switch. The switch is located in a bezel on the lower inboard side of the seat cushion frame. on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch unit cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and Operation > Page 6432 Power Seat Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the seat cushion. See Power Seat Switch Replacement. Power Seat Switch Continuity 3. Use an ohmmeter to test the continuity of the switches in each position. See the Power Seat Switch Continuity chart. If OK, see Power Seat Adjuster and Motors in the Diagnosis and Testing. If not OK, replace the faulty switch module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and Operation > Page 6433 Power Seat Switch: Service and Repair REMOVAL 1. Remove the driver side front seat from the power seat adjuster and motors unit. See Power Seat Adjuster and Motors Replacement. Power Seat Switch And Bezel Remove/Install 2. Remove the two screws that secure the power seat switch and bezel unit to the seat from the inside of the seat cushion frame. 3. Pull the power seat switch and bezel unit out from the outside of the seat cushion frame far enough to access the wire harness connector. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the locking tabs of the power seat switch unit away from the wire harness connector and carefully unplug the switch from the connector. 5. Remove the two screws that secure the power seat switch unit to the back of the switch bezel. 6. Remove the power seat switch from the bezel. 7. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Recalls: > 781 > May > 98 > Recall - Power Seat Riser Technical Service Bulletin # 781 Date: 980501 Recall - Power Seat Riser No. 781 May, 1998 To: All Dodge Truck Dealers Subject: Safety Recall # 781 -- Power Seat Riser Models: 1998 Model Year Dodge Ram (AB) Vans and Wagons Equipped With a Power Driver's Seat (Sales Code CDG or JPS) Built Through March 2, 1998 (MDH 030213) The power driver's seat riser on about 3,600 of the above listed vehicles, may have inadequate front crossmember spot welds. A seat riser with inadequate welds may allow the front crossmember to separate from the riser under certain accident conditions. To correct this condition, the power driver's seat riser must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using the DIAL VIP System. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Parts information is also provided. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD781". Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Seat Risers to service about 50% of those vehicles. Dealers should determine which part is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate seat riser for the vehicle to be serviced may be determined by: ^ Using the part code in the third column of the VIN list along with the table shown (involved dealers): ^ Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers) or ^ Entering the VIN to the DIAL VIP System (sales code information) along with the table shown (all dealers). Owner Notification and Service Scheduling Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Recalls: > 781 > May > 98 > Recall - Power Seat Riser > Page 6442 All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Allowance Number Replace power driver's seat riser 23781182 0.4 hours Add the cost of the recall parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure 1. With the ignition key in the OFF position, disconnect the battery. IMPORTANT: The battery must be disconnected as the airbag electronic control module (AECM) is located under the driver's seat. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the seat belt buckle assembly from the driver's seat riser. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Recalls: > 781 > May > 98 > Recall - Power Seat Riser > Page 6443 3. Using a trim panel removal tool, remove the push-in fasteners that attach the seat riser trim shield to the rear of the driver's seat riser (Figure 1). Set the trim shield aside. 4. Remove the power seat wiring harness connector from the front riser crossmember and then disconnect the connector (Figure 2). 5. Remove the nuts that attach the seat riser to the floor pan (Figure 2). 6. Remove the driver's seat from the vehicle. 7. Remove the nuts that attach the seat riser to the power seat track adjuster (Figure 2). Discard the seat riser. 8. Install the new seat riser on the power seat track adjuster (Figure 2). Tighten the nuts to 16 ft-lbs (22 N.m). 9. Install the seat assembly back into the vehicle. 10. Install the nuts that attach the seat riser to the floorpan (Figure 2). Tighten the nuts to 55 ft-lbs (75 N.m). 11. Connect the power seat wiring harness connector and attach it to the front riser crossmember. 12. Install the seat riser trim shield (Figure 1). 13. Install the seat belt buckle assembly on to the seat riser. Tighten the bolt to 29 ft-lbs (40 N.m). 14. Reconnect the negative battery cable. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Safety Recall # 781 -- Power Seat Riser ^ This service requirement applies only to 1998 model year Dodge Ram (AB) vans and wagons equipped with a power driver's seat (Sales Code -- CDG or JPS) built through March 2, 1998 (MDH 030213). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Recalls: > 781 > May > 98 > Recall - Power Seat Riser > Page 6444 ^ The power driver's seat riser on the above listed vehicles, may have inadequate front crossmember spot welds. To correct this condition, the power driver's seat riser must be replaced. ^ Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a CHRYSLER MOBILE SERVICE approved repair. Parts Packages: ^ Two (2) unique parts are required for this recall depending upon the interior color of the vehicle. Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough Seat Risers to service about 50% of those vehicles. Dealers should determine which part is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. Refer to the Parts section for details. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S POWER DRIVER'S SEAT RISER Dear Dodge Ram Van or Wagon Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1998 Dodge Ram Vans and Wagons equipped with a power driver's seat. The problem is... The power driver's seat riser (seat base) on your Ram van or wagon (identified on the enclosed form), may have been improperly manufactured and could have inadequate strength. The seat riser front crossmember may separate from the seat riser. This will cause increased injury to the driver of the vehicle under certain accident conditions. What Chrysler and your dealer will do... Chrysler will repair your Ram van or wagon free of charge (parts and labor). To do this, your dealer will replace the power driver's seat riser. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 1-202-366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 6448 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 6449 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 6450 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Capacity ............................................................................................................................................... ....................................................... 1.28 L (2.7 pints) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Component Information > Specifications > Capacity Specifications > Page 6453 Power Steering Fluid: Fluid Type Specifications The recommended lubricant is Mopar Power Steering Fluid. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Track: > 21-08-99 > Apr > 99 > Recalls for Seat Track: > 781 > May > 98 > Recall Power Seat Riser Technical Service Bulletin # 781 Date: 980501 Recall - Power Seat Riser No. 781 May, 1998 To: All Dodge Truck Dealers Subject: Safety Recall # 781 -- Power Seat Riser Models: 1998 Model Year Dodge Ram (AB) Vans and Wagons Equipped With a Power Driver's Seat (Sales Code CDG or JPS) Built Through March 2, 1998 (MDH 030213) The power driver's seat riser on about 3,600 of the above listed vehicles, may have inadequate front crossmember spot welds. A seat riser with inadequate welds may allow the front crossmember to separate from the riser under certain accident conditions. To correct this condition, the power driver's seat riser must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using the DIAL VIP System. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Parts information is also provided. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD781". Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Seat Risers to service about 50% of those vehicles. Dealers should determine which part is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate seat riser for the vehicle to be serviced may be determined by: ^ Using the part code in the third column of the VIN list along with the table shown (involved dealers): ^ Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers) or ^ Entering the VIN to the DIAL VIP System (sales code information) along with the table shown (all dealers). Owner Notification and Service Scheduling Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Track: > 21-08-99 > Apr > 99 > Recalls for Seat Track: > 781 > May > 98 > Recall Power Seat Riser > Page 6463 All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Allowance Number Replace power driver's seat riser 23781182 0.4 hours Add the cost of the recall parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure 1. With the ignition key in the OFF position, disconnect the battery. IMPORTANT: The battery must be disconnected as the airbag electronic control module (AECM) is located under the driver's seat. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the seat belt buckle assembly from the driver's seat riser. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Track: > 21-08-99 > Apr > 99 > Recalls for Seat Track: > 781 > May > 98 > Recall Power Seat Riser > Page 6464 3. Using a trim panel removal tool, remove the push-in fasteners that attach the seat riser trim shield to the rear of the driver's seat riser (Figure 1). Set the trim shield aside. 4. Remove the power seat wiring harness connector from the front riser crossmember and then disconnect the connector (Figure 2). 5. Remove the nuts that attach the seat riser to the floor pan (Figure 2). 6. Remove the driver's seat from the vehicle. 7. Remove the nuts that attach the seat riser to the power seat track adjuster (Figure 2). Discard the seat riser. 8. Install the new seat riser on the power seat track adjuster (Figure 2). Tighten the nuts to 16 ft-lbs (22 N.m). 9. Install the seat assembly back into the vehicle. 10. Install the nuts that attach the seat riser to the floorpan (Figure 2). Tighten the nuts to 55 ft-lbs (75 N.m). 11. Connect the power seat wiring harness connector and attach it to the front riser crossmember. 12. Install the seat riser trim shield (Figure 1). 13. Install the seat belt buckle assembly on to the seat riser. Tighten the bolt to 29 ft-lbs (40 N.m). 14. Reconnect the negative battery cable. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Safety Recall # 781 -- Power Seat Riser ^ This service requirement applies only to 1998 model year Dodge Ram (AB) vans and wagons equipped with a power driver's seat (Sales Code -- CDG or JPS) built through March 2, 1998 (MDH 030213). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Track: > 21-08-99 > Apr > 99 > Recalls for Seat Track: > 781 > May > 98 > Recall Power Seat Riser > Page 6465 ^ The power driver's seat riser on the above listed vehicles, may have inadequate front crossmember spot welds. To correct this condition, the power driver's seat riser must be replaced. ^ Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a CHRYSLER MOBILE SERVICE approved repair. Parts Packages: ^ Two (2) unique parts are required for this recall depending upon the interior color of the vehicle. Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough Seat Risers to service about 50% of those vehicles. Dealers should determine which part is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. Refer to the Parts section for details. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S POWER DRIVER'S SEAT RISER Dear Dodge Ram Van or Wagon Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1998 Dodge Ram Vans and Wagons equipped with a power driver's seat. The problem is... The power driver's seat riser (seat base) on your Ram van or wagon (identified on the enclosed form), may have been improperly manufactured and could have inadequate strength. The seat riser front crossmember may separate from the seat riser. This will cause increased injury to the driver of the vehicle under certain accident conditions. What Chrysler and your dealer will do... Chrysler will repair your Ram van or wagon free of charge (parts and labor). To do this, your dealer will replace the power driver's seat riser. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 1-202-366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 6470 Power Door Lock Switch: Description and Operation SYSTEM OPERATION The power locks can be controlled by a two-way switch mounted in a bezel on the mirror flag bezel trim of each front door. The power lock switch controls the battery feeds to the lock and unlock sense inputs of the power lock and Remote Keyless Entry (RKE) module or the Central Timer Module (CTM). The relays that are integral to the power lock and REE module or the CTM then direct the correct battery and ground feeds to the power lock motors. The power lock switches cannot be repaired and, if faulty or damaged, the switches must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 6471 Power Door Lock Switch: Testing and Inspection 1. Check the fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the power lock switch. 4. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power lock switch wire harness connector. If OK, go to Step 6. If not OK, repair the open circuit to the junction block as required. Power Lock Switch Continuity 5. Test the power lock switch continuity See the Power Lock Switch Continuity chart to determine if the continuity is correct in the Of,, Lock and Unlock switch positions. If OK, repair the door lock switch output (lock and/or unlock) circuit(s) from the power lock switch wire harness connector to the power lock and Remote Keyless Entry (RKE) module or to the Central Timer Module (CTM) as required. If not OK, replace the faulty switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 6472 Power Door Lock Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the mirror flag bezel from the inside of the front door. Power Lock Switch Remove/Install 3. From the back side of the mirror flag bezel, remove the screws that secure the power window and power lock switch and mounting plate unit to the mirror flag bezel. 4. Remove the power window and power lock switch and mounting plate unit from the mirror flag bezel. 5. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power lock switch receptacle on the back of the switch mounting plate and pull the switch out of the receptacle. 6. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the switch mounting plate are fully engaged. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation SYSTEM OPERATION Power Mirror Switch Both the right and left power outside mirrors are controlled by a single multi-function switch unit located on and mounted to the upper flag area of the driver side door trim panel. The switch knob is rotated clockwise (right mirror control), or counterclockwise (left mirror control) to select the mirror to be adjusted. The switch knob is then moved in a joystick fashion to control movement of the selected mirror up, down, right, or left. The power mirror switch cannot be repaired and, if faulty or damaged, it must be replaced. The power mirror switch knob is available for service replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 6476 Power Mirror Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Mirror Switch Knob Remove/Install 2. Pull the power mirror switch control knob rearward to remove it from the switch stem. Power Mirror Switch Nut 3. Remove the nut that secures the power mirror switch to the driver side door trim pane). 4. Remove the mirror flag bezel from the inside of the front door. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 6477 Power Mirror Switch Remove/Install 5. Unplug the power mirror switch wire harness connector. 6. Remove the power mirror switch from the back of the door mirror flag bezel. 7. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation Power Seat Switch: Description and Operation SYSTEM OPERATION Power Seat Switch The power seat can be adjusted in six different ways using the power seat switch. The switch is located in a bezel on the lower inboard side of the seat cushion frame. on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch unit cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 6481 Power Seat Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the seat cushion. See Power Seat Switch Replacement. Power Seat Switch Continuity 3. Use an ohmmeter to test the continuity of the switches in each position. See the Power Seat Switch Continuity chart. If OK, see Power Seat Adjuster and Motors in the Diagnosis and Testing. If not OK, replace the faulty switch module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 6482 Power Seat Switch: Service and Repair REMOVAL 1. Remove the driver side front seat from the power seat adjuster and motors unit. See Power Seat Adjuster and Motors Replacement. Power Seat Switch And Bezel Remove/Install 2. Remove the two screws that secure the power seat switch and bezel unit to the seat from the inside of the seat cushion frame. 3. Pull the power seat switch and bezel unit out from the outside of the seat cushion frame far enough to access the wire harness connector. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the locking tabs of the power seat switch unit away from the wire harness connector and carefully unplug the switch from the connector. 5. Remove the two screws that secure the power seat switch unit to the back of the switch bezel. 6. Remove the power seat switch from the bezel. 7. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 23-43-98 > Sep > 98 > Dual Cargo Door - Water Leak Diagnostic/Repair Procedure Technical Service Bulletin # 23-43-98 Date: 980918 Dual Cargo Door - Water Leak Diagnostic/Repair Procedure NO: 23-43-98 GROUP: Body DATE: Sep. 18, 1998 SUBJECT: Dual Cargo Door Water Leak Diagnostic/Repair Procedure MODELS: 1994 - 1999 (AB) Ram Van/Wagon DISCUSSION: This bulletin is intended to assist in identifying water leak entry points past the dual cargo door seals by highlighting areas where leaks are likely to occur based on the experience gained during the development of the vehicle. A thorough water test is required and the test will often readily show entry points which require repair. The bulletin is broken down by specific areas and provides illustrations as to where to look in these areas. The repair methods may vary depending on the situation you encounter but recommendations are provided for sealing the effected areas. PARTS REQUIRED: AR (1) 04773774 Adhesive, Weatherstrip AR (1) 04318025 Sealant, Silicone Rubber Adhesive AR (1) 03759944 Retainers AR (1) 55134553AC Weatherstrip, Side Cargo Door, First Closing Door AR (1) 55135270AB Weatherstrip, Side Cargo Door, Second Closing Door AR (1) 55134555AB Weatherstrip, Rear Cargo Door, First Closing Door AR (1) 55135271AB Weatherstrip, Rear Cargo Door, Second Closing Door AR (1) NPN Tape, High/Medium Density Closed Cell Foam (3M 06375 Or Equivalent) AR (1) NPN Tape, Open Cell Foam (3M p/n 62385 Or Equivalent) POLICY: Information Only Repair Procedure This bulletin involves locating points of water entry around the cargo doors and sealing the areas around the weatherstrips or replacing the weatherstrips on the side and/or rear dual cargo doors. FIRST CLOSING CARGO DOOR (LEFT DOOR - SIDE AND/OR REAR) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 23-43-98 > Sep > 98 > Dual Cargo Door - Water Leak Diagnostic/Repair Procedure > Page 6491 1. Inspect the cavity (Figure 1) on the upper inboard corner of the molded detail and top caliper latch for a small gap. This condition can leak water into the door and/or past the weatherstrip into the vehicle interior. If a gap is found, clean the area in and around the cavity then, seal the gap with Mopar Silicone Rubber Adhesive Sealant p/n 04318025. NOTE: ALLOW THE SEALANT TO CURE FOR AT LEAST 30 MINUTES BEFORE PERFORMING A VERIFICATION WATER TEST. 2. Inspect the front lower corner of the weatherstrip seal (Figure 1) to verify seal retention. The seal is held in place by a retainer. If the retainer is missing, replace it with a new retainer p/n 03759944 or the weatherstrip seal can be secured to the door inner panel with Mopar Weatherstrip Adhesive p/n 04773774. 3. Any water that may leak into the door will exit out the door through a drain located in the lower front corner of the door. The weatherstrip seal has a small hole in the seal to allow the water exiting out of the door drain to pass through the weatherstrip seal. Inspect the drain hole of the weatherstrip seal for a clear path from the door drain to the bottom of the seal. If the drain hole in the seal is restricted, open the hole up using a sharp object. SECOND CLOSING CARGO DOOR (RIGHT SIDE DOOR - SIDE AND/OR REAR) 1. Inspect the weatherstrip seal in the area where the seal passes over the middle and upper inboard character lines for a gap (Figure 2). A gap at the character lines may allow water to enter behind the seal and travel down the interior side of the seal and into the interior of the vehicle at the bottom of the door. If a gap is found, clean the area around the gap then, seal the gap with Mopar Silicone Rubber Adhesive Sealant p/n 04318025. NOTE: ALLOW THE SEALANT TO CURE FOR AT LEAST 30 MINUTES BEFORE PERFORMING A VERIFICATION WATER TEST. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 23-43-98 > Sep > 98 > Dual Cargo Door - Water Leak Diagnostic/Repair Procedure > Page 6492 2. Inspect the upper portion of the weatherstrip for a seal lip that may be bent over upon door closing (Figure 2). If the upper portion of the weatherstrip seal is bent over, replace the weatherstrip seal with p/n 55135270AB if the condition occurs on the side cargo door or p/n 55135271AB if the condition occurs on the rear cargo door. Refer to the appropriate Ram Van Service Manual Group 23 for information regarding cargo door weatherstrip seal service. NOTE: VERIFY THAT THE LIP OF THE NEW WEATHERSTRIP SEAL DOES NOT BEND OVER WHEN THE DOOR CLOSES. TRIM ANY EXCESS MATERIAL OFF THE LIP OF THE SEAL TO ENSURE THAT IT WILL NOT BEND OVER WHEN THE DOOR CLOSES. 3. Inspect the weatherstrip seal at the rear lower corner (Figure 2) of the door for a seal that squeezes out when the door closes. Use a foam stuffer glued to the hollow cavity behind the seal to repair the condition. The foam stuffer will allow the seal to retain its form. The foam stuffer should be made from a piece of 1/2 in. thick loose density foam such as 3M p/n 62385 Open Cell Foam Tape and glued with Mopar Weatherstrip Adhesive p/n 04773774. ALL CARGO DOORS 1. Inspect the weatherstrip seal at joints between the extruded bulb of the weatherstrip and the molded detail for wrinkles or other surface irregularities. Replace any weatherstrip seal if wrinkles or irregularities are found. Refer to the appropriate Ram Van Service Manual Group 23 for information regarding cargo door weatherstrip seal service. Once the seal has been replaced, verify that the sealing area of the new seal is smooth. 2. Inspect the backside of the weatherstrip seal at the header of the door (Figures 1 and 2) for a water leakpath. Either seal the backside of the weatherstrip with Mopar Silicone Rubber Adhesive Sealant p/n 04318025 or high/medium density foam tape 2-3 mm thick (such as 3M p/n 06375 or equivalent), cut to 12 mm wide X 630 mm long. If foam tape is used, make sure the ends of the foam are tapered so that there is no gaps created from the application of the foam tape. NOTE: ALLOW THE SEALANT TO CURE FOR AT LEAST 30 MINUTES BEFORE PERFORMING A VERIFICATION WATER TEST. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 23-43-98 > Sep > 98 > Dual Cargo Door - Water Leak Diagnostic/Repair Procedure Technical Service Bulletin # 23-43-98 Date: 980918 Dual Cargo Door - Water Leak Diagnostic/Repair Procedure NO: 23-43-98 GROUP: Body DATE: Sep. 18, 1998 SUBJECT: Dual Cargo Door Water Leak Diagnostic/Repair Procedure MODELS: 1994 - 1999 (AB) Ram Van/Wagon DISCUSSION: This bulletin is intended to assist in identifying water leak entry points past the dual cargo door seals by highlighting areas where leaks are likely to occur based on the experience gained during the development of the vehicle. A thorough water test is required and the test will often readily show entry points which require repair. The bulletin is broken down by specific areas and provides illustrations as to where to look in these areas. The repair methods may vary depending on the situation you encounter but recommendations are provided for sealing the effected areas. PARTS REQUIRED: AR (1) 04773774 Adhesive, Weatherstrip AR (1) 04318025 Sealant, Silicone Rubber Adhesive AR (1) 03759944 Retainers AR (1) 55134553AC Weatherstrip, Side Cargo Door, First Closing Door AR (1) 55135270AB Weatherstrip, Side Cargo Door, Second Closing Door AR (1) 55134555AB Weatherstrip, Rear Cargo Door, First Closing Door AR (1) 55135271AB Weatherstrip, Rear Cargo Door, Second Closing Door AR (1) NPN Tape, High/Medium Density Closed Cell Foam (3M 06375 Or Equivalent) AR (1) NPN Tape, Open Cell Foam (3M p/n 62385 Or Equivalent) POLICY: Information Only Repair Procedure This bulletin involves locating points of water entry around the cargo doors and sealing the areas around the weatherstrips or replacing the weatherstrips on the side and/or rear dual cargo doors. FIRST CLOSING CARGO DOOR (LEFT DOOR - SIDE AND/OR REAR) Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 23-43-98 > Sep > 98 > Dual Cargo Door - Water Leak Diagnostic/Repair Procedure > Page 6498 1. Inspect the cavity (Figure 1) on the upper inboard corner of the molded detail and top caliper latch for a small gap. This condition can leak water into the door and/or past the weatherstrip into the vehicle interior. If a gap is found, clean the area in and around the cavity then, seal the gap with Mopar Silicone Rubber Adhesive Sealant p/n 04318025. NOTE: ALLOW THE SEALANT TO CURE FOR AT LEAST 30 MINUTES BEFORE PERFORMING A VERIFICATION WATER TEST. 2. Inspect the front lower corner of the weatherstrip seal (Figure 1) to verify seal retention. The seal is held in place by a retainer. If the retainer is missing, replace it with a new retainer p/n 03759944 or the weatherstrip seal can be secured to the door inner panel with Mopar Weatherstrip Adhesive p/n 04773774. 3. Any water that may leak into the door will exit out the door through a drain located in the lower front corner of the door. The weatherstrip seal has a small hole in the seal to allow the water exiting out of the door drain to pass through the weatherstrip seal. Inspect the drain hole of the weatherstrip seal for a clear path from the door drain to the bottom of the seal. If the drain hole in the seal is restricted, open the hole up using a sharp object. SECOND CLOSING CARGO DOOR (RIGHT SIDE DOOR - SIDE AND/OR REAR) 1. Inspect the weatherstrip seal in the area where the seal passes over the middle and upper inboard character lines for a gap (Figure 2). A gap at the character lines may allow water to enter behind the seal and travel down the interior side of the seal and into the interior of the vehicle at the bottom of the door. If a gap is found, clean the area around the gap then, seal the gap with Mopar Silicone Rubber Adhesive Sealant p/n 04318025. NOTE: ALLOW THE SEALANT TO CURE FOR AT LEAST 30 MINUTES BEFORE PERFORMING A VERIFICATION WATER TEST. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 23-43-98 > Sep > 98 > Dual Cargo Door - Water Leak Diagnostic/Repair Procedure > Page 6499 2. Inspect the upper portion of the weatherstrip for a seal lip that may be bent over upon door closing (Figure 2). If the upper portion of the weatherstrip seal is bent over, replace the weatherstrip seal with p/n 55135270AB if the condition occurs on the side cargo door or p/n 55135271AB if the condition occurs on the rear cargo door. Refer to the appropriate Ram Van Service Manual Group 23 for information regarding cargo door weatherstrip seal service. NOTE: VERIFY THAT THE LIP OF THE NEW WEATHERSTRIP SEAL DOES NOT BEND OVER WHEN THE DOOR CLOSES. TRIM ANY EXCESS MATERIAL OFF THE LIP OF THE SEAL TO ENSURE THAT IT WILL NOT BEND OVER WHEN THE DOOR CLOSES. 3. Inspect the weatherstrip seal at the rear lower corner (Figure 2) of the door for a seal that squeezes out when the door closes. Use a foam stuffer glued to the hollow cavity behind the seal to repair the condition. The foam stuffer will allow the seal to retain its form. The foam stuffer should be made from a piece of 1/2 in. thick loose density foam such as 3M p/n 62385 Open Cell Foam Tape and glued with Mopar Weatherstrip Adhesive p/n 04773774. ALL CARGO DOORS 1. Inspect the weatherstrip seal at joints between the extruded bulb of the weatherstrip and the molded detail for wrinkles or other surface irregularities. Replace any weatherstrip seal if wrinkles or irregularities are found. Refer to the appropriate Ram Van Service Manual Group 23 for information regarding cargo door weatherstrip seal service. Once the seal has been replaced, verify that the sealing area of the new seal is smooth. 2. Inspect the backside of the weatherstrip seal at the header of the door (Figures 1 and 2) for a water leakpath. Either seal the backside of the weatherstrip with Mopar Silicone Rubber Adhesive Sealant p/n 04318025 or high/medium density foam tape 2-3 mm thick (such as 3M p/n 06375 or equivalent), cut to 12 mm wide X 630 mm long. If foam tape is used, make sure the ends of the foam are tapered so that there is no gaps created from the application of the foam tape. NOTE: ALLOW THE SEALANT TO CURE FOR AT LEAST 30 MINUTES BEFORE PERFORMING A VERIFICATION WATER TEST. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations Speed Control Servo Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6504 Speed Control Servo CONN Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6505 Cruise Control Servo: Description and Operation SYSTEM OPERATION The servo unit consists of a solenoid valve body, a vacuum servo and the mounting bracket. The Powertrain Control Module (PCM) controls the solenoid valve body. The solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum servo. A cable connects the servo with the throttle linkage. The servo unit cannot be repaired and is serviced only as a complete assembly Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6506 Cruise Control Servo: Testing and Inspection Speed Control Servo For complete speed control system diagnosis, refer to the appropriate Powertrain Diagnostic Procedures. To test the speed control servo only, refer to the following: The engine must be started and running for the following voltage tests. 1. Start engine. 2. Disconnect 4-way electrical connector at servo. 3. Turn speed control switch to ON position. Fig. 4 Servo Harness Connector 4. Check for battery voltage at pin-3 of wiring harness 4-way connector. This is the 12 volt feed from the stoplamp switch. When the brake pedal is depressed, voltage should not be present at pin-3. If voltage is not present with brake pedal not depressed, check for continuity between servo and stop lamp switch. Also check stop lamp switch adjustment. 5. Connect a small gauge jumper wire between the disconnected servo harness 4-way connector pin-3, and pin-3 on the servo. Check for battery voltage at pins-1, 2 and 4 of the servo. If battery voltage is not at these pins, replace the servo. 6. Turn ignition switch to OFF position. Check for continuity between disconnected servo harness 4way connector pin4 and a good ground. There should be continuity. If not OK, repair open circuit to ground as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6507 Cruise Control Servo: Service and Repair The speed control servo is bolted to the radiator/ grille support under the right headlamp. REMOVAL 1. Disconnect negative battery cable at battery. 2. Remove engine cover. 4. Disconnect servo cable at throttle body Refer to Servo Cable Replacement. 5. Remove right headlamp assembly. Refer to Lighting and Horns/ Headlamp Bulb Replacement Lamps for procedures. Speed Control Servo Location 6. Disconnect vacuum hose (line) at servo. 7. Disconnect electrical connector at servo. 8. Remove 2 servo mounting bracket bolts. Servo Cable Clip Remove/Install - Typical 9. Remove 2 mounting nuts holding servo cable sleeve to bracket. 10. Pull speed control cable sleeve and servo away from servo mounting bracket to expose cable retaining clip and remove clip. Note: The servo mounting bracket displayed in is a typical bracket and may/may not be applicable to this model vehicle. 11. Remove servo from mounting bracket. INSTALLATION 1. Position servo to mounting bracket. 2. Align hole in cable connector with hole in servo pin. Install cable-to-servo retaining clip. 3. Insert servo mounting studs through holes in servo mounting bracket. 4. Install servo-to-servo bracket mounting nuts and tighten to 8.5 N.m (75 in. lbs.) torque. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6508 5. Position servo assembly to body and install 2 bolts. Tighten bolts to 8.5 N.m (75 in. lbs.) torque. 6. Connect vacuum line at servo. 7. Connect electrical connector at servo. 8. Connect servo cable to throttle body. Refer to Servo Cable Replacement. 9. Before starting engine, operate accelerator pedal to check for any binding. 10. Install engine cover. 11. Install air cleaner housing. 12. Connect negative battery cable to battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation Cruise Control Servo Cable: Description and Operation SYSTEM OPERATION The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. This cable causes the throttle control linkage to open or close the throttle valve in response to movement of the vacuum servo diaphragm. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation > Page 6512 Cruise Control Servo Cable: Service and Repair REMOVAL 1. Disconnect negative battery cable at battery. 2. Remove engine cover. 3. Remove air cleaner assembly. Servo Cable Remove/Install 4. Using finger pressure only, remove speed control cable connector at throttle body bellcrank by pushing connector rearward off the bellcrank pin. DO NOT try to pull connector off perpendicular to the bellcrank pin. Connector will be broken. 5. Squeeze 2 tabs on sides of speed control cable at throttle body mounting bracket (locking plate) and push out of bracket. 6. Disconnect servo cable at speed control servo. Refer to Speed Control Servo Replacement. INSTALLATION 1. Install end of cable to speed control servo. Refer to Speed Control Servo Replacement. 2. Install cable into throttle body mounting bracket (snaps in). 3. Install speed control cable connector at throttle body bell crank pin (snaps on). 4. Before starting engine, operate accelerator pedal to check for any binding. 5. Install air cleaner assembly Refer to Air Cleaner. 6. Install engine cover. 7. Connect negative battery cable at battery. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Mounting Screws, Speed Control Switches Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6516 Speed Control Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6517 Cruise Control Switch: Description and Operation SYSTEM OPERATION Two separate speed control switch modules are mounted on the steering wheel to the left and right side of the driver's airbag module. Within the two switch modules, five momentary contact switches, supporting seven different speed control functions are used. The outputs from these switches are filtered into one input. The Powertrain Control Module (PCM) determines which output has been applied through resistive multiplexing. The input circuit voltage is measured by the PCM to determine which switch function has been selected. A speed control indicator lamp, located on the instrument panel cluster is energized by the PCM via the CCD Bus. This occurs when speed control system power has been turned ON, and the engine is running. The two switch modules are labeled: ON/OFF, SET, RESUME/ACCEL, CANCEL and COAST. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one individual switch fails, the switch module must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6518 Cruise Control Switch: Testing and Inspection For complete speed control system diagnosis, refer to the appropriate Powertrain Diagnostic Procedures. To test each of the speed control switches only, refer to the following: WARNING: BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL AND STEERING COLUMN COMPONENTS, YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT 2 MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect negative battery cable. Wait 2 minutes for airbag system capacitor to discharge. 2. Remove the two speed control switch modules from steering wheel. Refer to the removal/installation section for procedures. Speed Control Switch Continuity (Typical Switch Shown) 3. Check continuity of each individual speed control switch module as shown in chart. If OK, reinstall switch. If not OK, replace switch module assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6519 Cruise Control Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE INJURY. 1. Disconnect and isolate negative battery cable. 2. Remove airbag module. Refer to airbags Speed Control Switches 3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical connector at switch. INSTALLATION 1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to 1.5 N.m (14 in. lbs.) torque. 4. Install airbag module. Refer to airbags for procedures. 5. Connect negative battery cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description and Operation Cruise Control Vacuum Reservoir: Description and Operation SYSTEM OPERATION A vacuum reservoir is used to supply the vacuum needed to maintain proper speed control operation when engine vacuum drops, such as in climbing a grade while driving. A one-way check valve is used in the vacuum line between the reservoir and the vacuum source. This check valve is used to trap engine vacuum in the reservoir. On certain vehicle applications, this reservoir is shared with the heating/air-conditioning system. The vacuum reservoir cannot be repaired and must be replaced if faulty. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description and Operation > Page 6523 Cruise Control Vacuum Reservoir: Service and Repair Vacuum Reservoir Location The vacuum reservoir is attached to the right-inner fender located below the right headlamp. REMOVAL 1. Remove right headlamp assembly. Refer to Lighting and Horn/Headlamp Bulb Replacement. 2. Disconnect vacuum line at reservoir. 3. The reservoir is attached with one bolt (upper). The lower ear at bottom of reservoir fits into an access slot on fender support. Remove mounting bolt and remove reservoir from vehicle. INSTALLATION 1. Fit lower reservoir mounting ear into access slot on fender support. 2. Install upper bolt and tighten to 4 N.m (35 in. lbs.) torque. 3. Install vacuum line at reservoir. 4. Install right headlamp assembly Refer to Lighting and Horn/Headlamp Bulb Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Solenoid > Component Information > Description and Operation Cruise Control Vacuum Solenoid: Description and Operation SYSTEM OPERATION When all of the speed control parameters are met, and the SET button is pressed, the PCM actuates the vent solenoid and "duty-cycles" the vacuum solenoid to open the throttle and bring the vehicle up to target speed. When the vehicle is at target speed, it will actuate the vent solenoid with the vacuum solenoid de-activated to maintain the vehicle at target speed. When the vehicle is above target speed, the PCM will "duty-cycle" the vent solenoid with the vacuum solenoid still de-activated to close the throttle to return to target speed. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Mounting Screws, Speed Control Switches Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6531 Speed Control Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6532 Cruise Control Switch: Description and Operation SYSTEM OPERATION Two separate speed control switch modules are mounted on the steering wheel to the left and right side of the driver's airbag module. Within the two switch modules, five momentary contact switches, supporting seven different speed control functions are used. The outputs from these switches are filtered into one input. The Powertrain Control Module (PCM) determines which output has been applied through resistive multiplexing. The input circuit voltage is measured by the PCM to determine which switch function has been selected. A speed control indicator lamp, located on the instrument panel cluster is energized by the PCM via the CCD Bus. This occurs when speed control system power has been turned ON, and the engine is running. The two switch modules are labeled: ON/OFF, SET, RESUME/ACCEL, CANCEL and COAST. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one individual switch fails, the switch module must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6533 Cruise Control Switch: Testing and Inspection For complete speed control system diagnosis, refer to the appropriate Powertrain Diagnostic Procedures. To test each of the speed control switches only, refer to the following: WARNING: BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL AND STEERING COLUMN COMPONENTS, YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT 2 MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect negative battery cable. Wait 2 minutes for airbag system capacitor to discharge. 2. Remove the two speed control switch modules from steering wheel. Refer to the removal/installation section for procedures. Speed Control Switch Continuity (Typical Switch Shown) 3. Check continuity of each individual speed control switch module as shown in chart. If OK, reinstall switch. If not OK, replace switch module assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6534 Cruise Control Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE INJURY. 1. Disconnect and isolate negative battery cable. 2. Remove airbag module. Refer to airbags Speed Control Switches 3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical connector at switch. INSTALLATION 1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to 1.5 N.m (14 in. lbs.) torque. 4. Install airbag module. Refer to airbags for procedures. 5. Connect negative battery cable. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Description and Operation Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation VEHICLE SPEED AND DISTANCE-PCM INPUT The Vehicle Speed Sensor (VSS) is no longer used for any Dodge truck in the 1998 model year. Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for fuel system and speed control system operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Service and Repair > With Four Wheel Antilock Brakes Vehicle Speed Sensor/Transducer - Cruise Control: Service and Repair With Four Wheel Antilock Brakes REMOVAL 1. Raise and support vehicle. Rear Wheel Speed Sensor 2. Disconnect wire from rear sensor on axle housing. 3. Remove sensor and bracket mounting bolt and remove sensor and bracket. INSTALLATION 1. Secure sensor wire to rear brake hose with clips provided. 2. Install sensor and mounting bracket in axle housing. Install mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Connect wire to sensor and secure wire to mounting bracket. 4. Remove support and lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Service and Repair > With Four Wheel Antilock Brakes > Page 6540 Vehicle Speed Sensor/Transducer - Cruise Control: Service and Repair With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 0-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Description and Operation Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation VEHICLE SPEED AND DISTANCE-PCM INPUT The Vehicle Speed Sensor (VSS) is no longer used for any Dodge truck in the 1998 model year. Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for fuel system and speed control system operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Service and Repair > With Four Wheel Antilock Brakes Vehicle Speed Sensor/Transducer - Cruise Control: Service and Repair With Four Wheel Antilock Brakes REMOVAL 1. Raise and support vehicle. Rear Wheel Speed Sensor 2. Disconnect wire from rear sensor on axle housing. 3. Remove sensor and bracket mounting bolt and remove sensor and bracket. INSTALLATION 1. Secure sensor wire to rear brake hose with clips provided. 2. Install sensor and mounting bracket in axle housing. Install mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Connect wire to sensor and secure wire to mounting bracket. 4. Remove support and lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Service and Repair > With Four Wheel Antilock Brakes > Page 6546 Vehicle Speed Sensor/Transducer - Cruise Control: Service and Repair With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 0-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > General Information ABS Light: Description and Operation General Information SYSTEM OPERATION The Anti-Lock Brake System (ABS)lamp gives an indication when the ABS system is faulty or inoperative. The lamp is controlled by the instrument cluster circuitry based upon messages received from the Controller Anti-lock Brake (CAB) on the Chrysler Collision Detection (CCD) data bus. The lamp is turned on by the CAB for about two seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the CAB turns the lamp on or off based upon the results of the ABS self-tests. The CAB continually monitors the ABS circuits and sensors to decide whether the system is in good operating condition. The CAB then sends the proper messages to the instrument cluster on the CCD data bus to turn the lamp on or off. If the CAB turns the lamp on after the bulb test, it indicates that the CAB has detected a system malfunction and/or that the ABS system has become inoperative. If only the amber ABS lamp is illuminated, and the red brake warning lamp remains off, the base brake system will operate normally. Each time the instrument cluster circuitry receives a lamp-on message from the CAB, it will light the lamp for the duration of the ABS malfunction. The CAB will also flash this lamp during the diagnostic mode, unless a hard fault is present. If a hard fault is present, the ABS lamp will illuminate without flashing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > General Information > Page 6552 ABS Light: Description and Operation Rear Wheel Antilock Brakes The amber ABS warning lamp is used to alert the driver of an RWAL problem and identify Diagnostic Trouble Codes (DTCs) stored in the Controller Antilock Brake (CAB's) memory. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > General Information > Page 6553 ABS Light: Description and Operation Four Wheel Antilock Brakes The amber ABS warning lamp is located in the instrument cluster. The lamp illuminates at start-up to perform a self check. The lamp goes out when the self check program determines the system is operating normal. If an ABS component exhibits a fault the Controller Antilock Brake (CAB) will illuminate the lamp and register a trouble code in the microprocessor. The lamp is controlled by the CAB. The CAB controls the lamp sending a message to the instrument cluster. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Testing and Inspection > Pinpoint Tests ABS Light: Pinpoint Tests Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Testing and Inspection > Pinpoint Tests > Page 6556 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Testing and Inspection > Pinpoint Tests > Page 6557 ABS Light: Component Tests and General Diagnostics The diagnosis found here addresses an inoperative Anti-lock Brake System (ABS) lamp condition. If the ABS lamp stays on with the ignition switch in the On position, or comes on and stays on while driving. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the ABS lamp fails to light when the ignition switch is turned to the On position, replace the ABS lamp bulb with a known good unit. If the ABS lamp still fails to operate, diagnosis of the ABS system and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool as described in the proper Diagnostic Procedures. For further diagnosis of the ABS lamp and the instrument cluster circuitry, see Instrument Cluster in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Locations Steering Column Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6563 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6564 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6565 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6566 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6567 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6568 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6569 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6570 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6571 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6572 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6573 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6574 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6575 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6576 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6577 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6578 Audible Warning Device: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6579 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6580 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6581 Chime Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > System Operation Audible Warning Device: Description and Operation System Operation SYSTEM OPERATION Central Timer Module A Central Timer Module (CTM) is used on this vehicle when it is equipped with the optional Vehicle Theft Security System (VTSS). In addition to serving as the security system module, the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, and a Remote Keyless Entry (RKE) module in a single unit. The CTM is also able to control and integrate many of the additional electronic functions and features included on models with this option. The CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. Intermittent wipe, wipe-after-wash, and speed sensitive intermittent wipe are some of the features that the CTM supports. The intermittent wipe relay is one of the outputs that the CTM can control. The CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). The CTM is mounted under the instrument panel, to the inboard side of the left center instrument panel support. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Central Timer Module Replacement. For diagnosis of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic procedures manual are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > System Operation > Page 6584 Audible Warning Device: Description and Operation Chime System Operation The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for gauge problems and tell tale warnings. The CTM chime functions will have priority over the MIC chime requests. There are two chime rates, Low; 50 chimes per minute for reminders and High; 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the driver door is open or the headlights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for the key-in, and headlamp warning; as long as the driver's door is open. The seat belt warning chime is activated for 4 to 6 seconds, and all other chime conditions will activate the chime once at the same time the warning light on the cluster is illuminated. The chime will sound for the following conditions: High Rate - Key in Warning-ignition off, key in ignition, driver's door open - Ignition off, headlamps on, driver's door open Low Rate - Seat belt warning-6 seconds after key on (6 to 8 chimes) or until seatbelt is buckled - Airbag lamp illuminated (3 times after prove-out) - ABS lamp illuminated (2 chimes after prove-out if equipped) - Check engine lamp illuminated (2 chimes after prove-out) - Check gauges lamp illuminated (2 chimes) - Engine Temp-High-when gauge enters red zone (2 chimes) - Low fuel - when fuel level reaches 1/8 tank (2 chimes) - Low washer fluid (2 chimes) - Transmission Temperature High (2 chimes) If the ignition switch is turned to the run/start position and the driver's door is closed, then opened, the warning chime is defeated. This allows the doors to be open without the warning chime constantly sounding. The CTM stays in this mode until the ignition switch is turned to the "off" position, then normal function will be restored. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6589 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6590 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6591 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6592 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6593 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6594 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6595 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6596 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6597 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6598 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6599 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6600 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6601 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6602 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6603 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6604 Audible Warning Device Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6605 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6606 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6607 Audible Warning Device Control Module: Electrical Diagrams 8w-45-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6608 8w-45-3 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6609 8w-45-4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6610 8w-45-5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6611 8w-45-6 NOTE: To view Diagrams referred to in these diagrams SEE Complete Body and Chassis Diagrams.. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 6612 Audible Warning Device Control Module: Description and Operation SYSTEM OPERATION A Central Timer Module (CTM) is used on this vehicle when it is equipped with the optional Vehicle Theft Security System (VTSS). In addition to serving as the security system module, the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, and a Remote Keyless Entry (RKE) module in a single unit. The CTM is also able to control and integrate many of the additional electronic functions and features included on models with this option. The CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The horn relay is one of the outputs that the CTM can control. The CTM is programmed to energize or de-energize the horn relay in response to certain inputs from the Vehicle Theft Security System (VTSS) and the Remote Keyless Entry (RKE) system. Refer to Body and Frame/Locks/Power Locks Systems for more information on the RKE system. Refer to Accessories and Optional Equipment/Antitheft and Alarm Systems/Vehicle Theft/Security Systems for more information on the VTSS. The CTM is mounted under the instrument panel, to the inboard side of the left center instrument panel support. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Central Timer Module Replacement For diagnosis of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. The CTM controls features and functions of the power lock, illuminated entry, and Remote Keyless Entry (RKE) systems. The CTM receives hard wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio frequency inputs from the RKE transmitters. In response to those and many other inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the headlamp and horn relays, and the courtesy lamps. The RKE receiver within the CTM has a memory function to retain the vehicle access codes of at least one, but no more than four RKE transmitters. The receiver is designed to retain the transmitter codes in memory, even if the battery is disconnected. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the REE transmitter. - A delay lock feature. With the delay lock feature, if a side or rear door is still open when a lock request is received by the CTM, the module will automatically cycle all of the power lock motors to lock five seconds after the doors are closed. - An enhanced accident response feature will unlock all doors, then prevent the power door lock system from locking the doors for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors and the liftgate after the vehicle reaches a speed of about 24 kilometers-per- hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. The CTM is mounted under the instrument panel, to the inboard side of the left center instrument panel support. Refer to Central Timer Module Replacement. The programmable features of the CTM can be enabled or disabled using the DRB scan tool as described in the proper Diagnostic Procedures. For diagnosis of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. A Central Timer Module (CTM) is used on this vehicle when it is equipped with the optional Vehicle Theft Security System (VTSS). In addition to serving as the security system module, the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, and a Remote Keyless Entry (RKE) module in a single unit. The CTM is also able to control and integrate many of the additional electronic functions and features included on models with this option. The CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 6613 hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. One of the features that the CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard--wired inputs from the door ajar, front door lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp (or security) relay, horn relay; and the security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS. The CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering function; of the VTSS. The CTM is mounted under the instrument panel, to the inboard side of the left center instrument panel support. Refer to Instrument Panel, Gauges and Warning Indicators/Audible Warning Device Control Module/ Central Timer Module Replacement. The programmable features of the CTM can be enabled or disabled using the DRB scan tool as described in the proper Diagnostic Procedures. For diagnosis of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 6614 Audible Warning Device Control Module: Testing and Inspection NOTE: The following tests may not prove conclusive in the diagnosis of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the CTM requires the use of a DRB scan tool. The CTM is used on models that are equipped with the optional Vehicle Theft Security System (VTSS). If the problem being diagnosed involves only the RKE horn chirp feature, see Horn Relay in the Diagnosis and Testing. If the relay checks OK; or if the problem being diagnosed involves the rolling door locks, door lock inhibit, or enhanced accident response features, further diagnosis of the CTM should be performed using a DRB scan tool. 1. Check the fused B(+) fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Check the fused ignition switch output fuse in the junction block. If OK, go to Step 5. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 4. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output fuse in the junction block. If OK, turn the ignition switch to the Off position and go to Step 6. If not OK, repair the open circuit to the ignition switch as required. 5. Disconnect and isolate the battery negative cable. Access and unplug the CTM wire harness connectors. Refer to Instrument Panel, Gauges and Warning Indicators/Audible Warning Device Control Module/Central Timer Module Replacement. 6. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 8. If not OK, repair the connections as required. 7. Probe the ground circuit cavity in the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity If OK, go to Step 9. If not OK, repair the open circuit(s) to ground as required. 8. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity in the 14-way CTM wire harness connector. If OK, go to Step 10. If not OK, repair the open circuit to the fuse in the junction block as required. 9. Probe the door lock switch output (lock) circuit cavity in the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 11. If not OK, repair the open circuit from either or both power lock switch(s) to the CTM as required. 10. Probe the door lock switch output (unlock) circuit cavity in the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 12. If not OK, repair the open circuit from either or both power lock switch(s) to the CTM as required. 11. Disconnect and isolate the battery negative cable. Reinstall the wire harness connectors to the CTM. Connect the battery negative cable. Back probe the door lock driver circuit cavity in the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 13. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 12. Still back probing the door lock driver circuit cavity in the 18-way CTM wire harness connector, open the side or rear cargo door. Move the power lock switch to the Lock position or press the Lock button of the RKE transmitter. Now close all of the doors. Within five seconds of the last door closing, there should be battery voltage on the door lock driver circuit. If OK, go to Step 14. If not OK, replace the faulty CTM. 13. Back probe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter If OK. see Power Lock Motor in the Diagnosis and Testing. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 6615 Audible Warning Device Control Module: Service and Repair A Central Timer Module (CTM) is only used on high-line versions of this vehicle that are also equipped with the Vehicle Theft Security System (VTSS). See Central Timer Module in the General information. Before replacing a CTM, use a DRB scan tool to determine the current settings for tile CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the engine cover from the passenger compartment. Central Timer Module Remove/Install 3. Remove the three screws that secure the CTM to the inboard side of the left center instrument panel support. 4. Pull the CTM away from its mounting location far enough to access and unplug the two wire harness connectors. 5. Remove the CTM from the instrument panel. 6. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). NOTE: If a new Central Timer Module is installed, the programmable features must be enabled and or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark 20 ABS System Test Revisions NUMBER: 26-12-97I GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Teves Mark 20 ABS Diagnostic Manual - Publication Number - 81-699-97013 DESCRIPTION OF CHANGES Revisions to the ABS warning lamp test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 6620 94 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 6621 95 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 6622 Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions NUMBER: 26-12-97F GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997-1998 Teves Mark IV, Teves Mark 20 ABS Diagnostic Manual - Publication Number 81-699-97012 DESCRIPTION OF CHANGES Revisions to the ABS warning light procedure Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 6623 244 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 6624 245 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > General Information Brake Warning Indicator: Description and Operation General Information SYSTEM OPERATION The brake warning lamp gives an indication when the parking brake is applied, when the pressures in the two halves of the split brake hydraulic system are unequal, if the Anti-lock Brake System (ABS) lamp has failed and an ABS fault occurs, and during ABS diagnostics. The lamp is turned on by the instrument cluster circuitry for about two seconds when the ignition switch is moved to the Start position as a bulb test. After the bulb test, the lamp is controlled by a hard wired input from the parking brake switch and/or by the instrument cluster circuitry based upon messages received from the Controller Anti-lock Brake (CAB) on the Chrysler Collision Detection (CCD) data bus. The CAB turns the lamp on or off based upon the results of the ABS self-tests. The CAB continually monitors the ABS circuits and sensors, including the brake warning switch and the ABS lamp, to decide whether the system is in good operating condition. The CAB then sends the proper messages to the instrument cluster on the CCD data bus to turn the lamp on or off. If the CAB turns the lamp on after the bulb test, it indicates that the CAB has detected a system malfunction. The parking brake switch is hard wired to the instrument cluster and closes to ground when the parking brake is applied. The brake warning switch is hard wired to the CAB and closes to ground when it senses unequal hydraulic pressures in the two halves of the split brake hydraulic system, possibly due to low brake fluid level or brake fluid leakage. After the bulb test, if the red brake warning lamp remains illuminated with the parking brake released, the base brake system may not be operational. The vehicle should never be operated while the red brake warning lamp is illuminated. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > General Information > Page 6627 Brake Warning Indicator: Description and Operation Brake Warning Lamp Description The red brake warning lamp is used to alert the driver of a hydraulic fault or that the parking brake is applied. For the RWAL system, the red brake warning lamp also is used to alerts the driver of a problem with the RWAL system. The brake warning lamp illuminates when a message is sent over the bus to the cluster to illuminate the bulb. A ground for the bulb is provided when: - The brakes are applied and the park brake switch is actuated. - A hydraulic fault has occurred and the pressure differential switch is actuated. - A RWAL fault has occurred. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Page 6628 Brake Warning Indicator: Testing and Inspection The diagnosis found here addresses an inoperative brake warning lamp condition. If the brake warning lamp stays on with the ignition switch in the On position and the parking brake released, or comes on while driving, WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the wire harness connector at the park brake switch. With the park brake released, check for continuity between the park brake switch terminal and a good ground. There should be no continuity If OK, go to Step 5. If not OK, adjust or replace the faulty park brake switch. 4. Remove the instrument cluster. With the park brake switch wire harness connector still unplugged, check for continuity between the park brake switch wire harness connector cavity and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the short circuit as required. 5. Check for continuity between the park brake switch sense circuit cavities of the instrument cluster wire harness connector (connector A) and the park brake switch wire harness connector, There should be continuity. If OK, see Instrument Cluster in the Diagnosis and Testing for further testing of the brake warning lamp and the instrument cluster circuitry. If not OK, repair the open circuit as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Description and Operation Check Gauges Lamp: Description and Operation SYSTEM OPERATION The check gauges lamp gives an indication when certain gauges reflect a condition requiring immediate attention. The lamp is turned on by the instrument cluster circuitry for about three seconds after the ignition switch is turned to the On position as a bulb test. After the bulb test, the lamp is controlled by the instrument cluster circuitry based upon gauge data messages received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses several inputs to decide what gauge data messages are required. The PCM then sends the proper message to the instrument cluster on the CCD data bus. When the instrument cluster circuitry receives a gauge data message that requires the check gauges lamp to be turned on, it also sends a chime tone request to the Central Timer Module (CTM). The gauge data messages for which the instrument cluster is programmed to turn on the check gauges lamp are: Engine coolant temperature is high - Engine oil pressure is low - System voltage is high or low. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Description and Operation > Page 6632 Check Gauges Lamp: Testing and Inspection The diagnosis found here addresses an inoperative check gauges lamp condition. If the check gauges lamp stays on with the ignition switch in the On position, or comes on while driving with no unusual gauge readings evident, diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the coolant temperature gauge, oil pressure gauge, or voltmeter are giving an indication that should trigger the check gauges lamp, but the check gauges lamp still fails to operate, refer to Instrument Panel/Testing and Inspection for further diagnosis of the check gauges lamp and the instrument cluster circuitry. See: Instrument Cluster / Carrier/Testing and Inspection Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6637 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6638 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6639 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6640 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6641 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6642 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6643 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6644 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6645 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6646 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6647 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6648 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6649 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6650 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6651 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6652 Cigarette Lighter: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6653 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6654 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6655 Cigarette Lighter: Description and Operation SYSTEM OPERATION A cigar lighter is available equipment on this model. The cigar lighter is installed in the instrument panel accessory switch plate, which is located near the center of the instrument panel, inboard of the radio. The cigar lighter base is secured by a clamp on the back of the instrument panel accessory switch plate. The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter receives battery voltage from a fuse in the junction block only when the ignition switch is in the Accessory or On positions. The knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating dement are inserted in the receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating dement, and the heating element extends from the housing toward the insulated contact in the bottom of the receptacle shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the receptacle shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. The cigar lighter knob and heating element unit, and the cigar lighter receptacle unit are available for service. These components cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6656 Cigarette Lighter: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 3. Turn the ignition switch to the Off position. Remove the cigar lighter knob and element from the cigar lighter receptacle. Check for continuity between the inside circumference of the cigar lighter receptacle and a good ground. There should be continuity If OK, go to Step 5. If not OK, go to Step 6. 4. Turn the ignition switch to the On position. Check for battery voltage at the insulated contact located at the back of the cigar lighter receptacle. If OK, replace the faulty cigar lighter knob and element. If not OK, go to Step 6. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the instrument panel accessory switch plate. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground. There should be continuity If OK, go to Step 7. If not OK, repair the open circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run/accessory) circuit cavity of the cigar lighter wire harness connector. If OK, replace the faulty cigar lighter receptacle. If not OK, repair the open circuit to the junction block fuse as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6657 Cigarette Lighter: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the accessory switch plate from the instrument panel. See Accessory Switch Plate Replacement. Cigar Lighter And Power Outlet 3. Pull the cigar lighter knob and element out of the cigar lighter receptacle base. 4. Unscrew the shell clamp that secures the cigar lighter receptacle base to the back of the accessory switch plate. 5. Pull the cigar lighter receptacle base out from the front of the accessory switch plate. 6. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Description and Operation Cruise Control Indicator Lamp: Description and Operation SYSTEM OPERATION The cruise-on indicator lamp gives an indication when the vehicle speed control system is turned on even when the system is not currently engaged. The lamp is turned on by the instrument cluster circuitry for about two seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the lamp is controlled by the instrument cluster circuitry based upon messages received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the analog resistor-multiplexed vehicle speed control switches in the steering wheel to decide whether to turn the lamp on or off. The PCM then sends the proper messages to the instrument cluster on the CCD data bus. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Description and Operation > Page 6661 Cruise Control Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative cruise-on indicator lamp condition. If the problem being diagnosed is an inaccurate cruise-on indicator lamp, refer to Cruise Control/Vehicle Speed Control for diagnosis of the vehicle speed control system. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the cruise-on indicator lamp fails to light during the bulb test (about two seconds after the ignition switch is turned to the On position), replace the cruise-on indicator lamp bulb with a known good unit. If the cruise-on lamp still fails to operate, diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For further diagnosis of the cruise-on indicator lamp and the instrument cluster circuitry, refer to Instrument Panel/Testing and Inspection. See: Instrument Cluster / Carrier/Testing and Inspection Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: The airbag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the airbag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the airbag and possible personal injury. The fasteners, screws, and bolts, originally used for the airbag components, have special coatings and are specifically designed for the airbag system. They must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books . Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6666 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams Door Switch: Diagrams Left Front Door Ajar Switch Connector Right Front Door Ajar Switch Connector Auxiliary Door Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 6670 Auxiliary Door Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation Fuel Gauge: Description and Operation SYSTEM OPERATION The fuel gauge gives an indication of the level of fuel in the fuel tank. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon fuel level messages received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the fuel gauge sending unit and internal programming to decide what fuel level messages are required. The PCM then sends the proper messages to the instrument cluster on the CCD data bus. If the PCM messages indicate that the fuel level is below one-eighth of a full tank for more than ten seconds (60 seconds if the vehicle speed input is greater than zero miles-per-hour), the instrument cluster circuitry turns on the low fuel warning lamp and sends a chime tone request to the Central Timer Module (CTM). The fuel gauge sending unit is mounted to the electric fuel pump module located inside the fuel tank. The sending unit has a float attached to the end of a swing-arm. The float moves up or down within the fuel tank as the fuel level changes. As the float moves, an electrical contact on the pivot end of the swing-arm wipes across a resistor coil, which changes the internal electrical resistance of the sending unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Page 6674 Fuel Gauge: Testing and Inspection If the problem being diagnosed is related to fuel gauge accuracy, be certain to confirm that the problem is with the gauge or sending unit and not with the fuel tank. Inspect the fuel tank for signs of damage or distortion that could affect the sending unit performance before you proceed with fuel gauge diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Diagnosis of the fuel gauge sending unit and circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For further diagnosis of the fuel gauge and the instrument cluster circuitry, refer to Instrument Panel/Testing and Inspection. See: Instrument Cluster / Carrier/Testing and Inspection Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions Fuel Gauge Sender: Technical Service Bulletins Engine Controls/Fuel System - Service Manual Revisions NUMBER: 26-12-97H GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L, 3.9L, 5.2L, 8.0L Powertrain Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the "No Cam Signal at PCM" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page 6679 29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page 6680 56 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page 6681 58 Revision to the "Fuel Level Sending Unit" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page 6682 412 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6683 Fuel Gauge Sender: Description and Operation DESCRIPTION The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a vanable resistor (track). The resistor track is used to send electrical signals to the Powertrain Control Module (PCM) for fuel gauge operation and for OBD II emission requirements. OPERATION For fuel gauge operation: As fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This increases the sending unit resistance causing the fuel gauge to read empty. After this fuel level signal is sent to the PCM, the PCM will transmit the data across the CCD bus circuits to the instrument panel. Here it is translated into the appropriate fuel gauge level reading. For OBD II emission monitor requirements: A voltage signal is sent from the resistor track on the sending unit to the PCM to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6684 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. To test the gauge sending unit only, it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal Installation for procedures. Measure the resistance across the sending unit terminals. With float in up position, resistance should be 20 ohms ± 6 ohms. - With float in down position, resistance should be 220 ± 6 ohms. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6685 Fuel Gauge Sender: Service and Repair Fig 30 Fuel Gauge Sending Unit Location The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located on top of fuel tank. REMOVAL 1. Remove fuel tank. 2. Remove fuel pump module. 3. Carefully separate the lower section of pump module from upper section by releasing three module lock tabs. Take care not to stretch plastic fuel line within module. 4. Unplug 6-way electrical connector. 5. Disconnect 2 sending unit wires at 6-way connector. Note location of wires within 6-way connector. Fig 31 Fuel Gauge Sending Lock Tab/Tracks 6. The sending unit is retained to pump module with a small lock tab and notch. Carefully pry up on lock tab to release from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 6-way connector. 4. Connect 6-way electrical connector to module. 5. Carefully connect lower section of pump module to upper section (3 tabs lock upper section to lower section). 6. Install fuel pump module. 7. Install fuel tank. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: The airbag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the airbag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the airbag and possible personal injury. The fasteners, screws, and bolts, originally used for the airbag components, have special coatings and are specifically designed for the airbag system. They must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books . Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6690 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Description and Operation Instrument Panel Bulb: Description and Operation SYSTEM OPERATION Cluster Illumination Lamp The cluster illumination lamps are hard wired in the instrument cluster. When the park or head lamps are turned on, the cluster illumination lamps light. Illumination brightness is adjusted by rotating the headlamp switch knob (clockwise to dim, counterclockwise to brighten). The instrument cluster illumination lamps receive battery feed from the panel dimmer rheostat in the headlamp switch through a fuse in the junction block. Each of the cluster illumination lamps is located on the instrument cluster circuit board. Each lamp has a replaceable bulb and bulb holder. Refer to Lighting and Horns/Lamps for more information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Description and Operation > Page 6694 Instrument Panel Bulb: Testing and Inspection The diagnosis found here addresses an inoperative instrument cluster illumination lamp condition. If the problem being diagnosed includes inoperative exterior lighting controlled by the headlamp switch, that system needs to be repaired first. 1f the exterior lamps controlled by the headlamp switch are inoperative, refer to Lighting and Horns/Lamps for diagnosis. If no exterior lighting system problems are found, the following procedure will help locate a short or open in the cluster illumination lamp circuit. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the park lamps on with the headlamp switch. Rotate the headlamp switch knob counterclockwise to just before the interior lamps detent. Check for battery voltage at the fuse in the junction block. Rotate the headlamp switch knob clockwise while observing the test voltmeter. The reading should go from battery voltage to zero volts. If OK, go to Step 4. If not OK, repair the open circuit to the headlamp switch or refer to Lighting and Horns/Lamps to diagnose the headlamp switch. 3. Disconnect and isolate the battery negative cable. Remove the instrument cluster. Turn the headlamp switch off. Remove the fuse from the junction block. Probe the fused panel lamp dimmer switch signal circuit cavity of the instrument cluster wire harness connector (connector B). Check for continuity to a good ground. There should be no continuity If OK, go to Step 5. If not OK, repair the short circuit as required. 4. Reinstall the fuse in the junction block. Connect the battery negative cable. Turn the park lamps on with the headlamp switch. Rotate the headlamp switch knob counterclockwise to just before the interior lamps detent. Check for battery voltage at the fused panel lamp dimmer switch signal circuit cavity of the instrument cluster wire harness connector (connector B). If OK, replace the faulty bulb(s) and bulb holder(s). If not OK, repair the open circuit as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Description and Operation > Page 6695 Instrument Panel Bulb: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the instrument cluster from the instrument panel. See Instrument Cluster Replacement. Cluster Bulb Remove/Install 2. Remove the bulb and bulb holder from the circuit board on the rear of the instrument cluster housing by turning the holder counterclockwise. CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the instrument cluster circuit board and/or the gauges. 3. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation Low Fuel Lamp/Indicator: Description and Operation SYSTEM OPERATION Low Fuel Warning Lamp The low fuel warning lamp gives an indication when the fuel level in the fuel tank has fallen below about one-eighth of a full tank, as registered on the fuel gauge. The instrument cluster circuitry lights the lamp for about two seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the instrument cluster circuitry controls the lamp based upon fuel level and vehicle speed messages received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses inputs from the fuel gauge sending unit, the Controller Anti-lock Brake (CAB), and internal programming to decide what messages are required. The PCM then sends the proper messages to the instrument cluster on the CCD data bus. If the PCM messages indicate that the fuel level is below one-eighth of a full tank for more than ten seconds, and that the vehicle is not moving, the instrument cluster circuitry turns on the low fuel warning lamp and sends a chime tone request to the Central Timer Module (CTM). To reduce the effects of fuel sloshing, if the vehicle speed message indicates that the vehicle is moving, the fuel level message must remain below one-eighth of a full tank for more than sixty seconds before the lamp will be illuminated. The fuel gauge sending unit is mounted to the electric fuel pump module inside the fuel tank. The sending unit has a float attached to the end of a swing-arm. The float moves up or down within the fuel tank as the fuel level changes. As the float moves an electrical contact on the pivot end of the swing-arm wipes across a resistor coil, which changes the resistance of the sending unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Page 6699 Low Fuel Lamp/Indicator: Testing and Inspection The diagnosis found here addresses an inoperative low fuel warning lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm the problem is the with the low fuel warning lamp and not with the fuel gauge circuit. Refer to Instrument Panel, Gauges and Warning Indicators/Fuel Gauge/Testing and Inspection. If no fuel gauge problem is found, see Instrument Panel/Testing and Inspection. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the low fuel warning lamp fails to light during the bulb test (about two seconds after the ignition switch is turned to the On position), replace the low fuel warning lamp bulb with a known good unit. If the indicator lamp still fails to operate, diagnosis of the fuel gauge sending unit and circuit, the Powertrain Control Module (PCM), and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool as described in the proper Diagnostic Procedures manual. For further diagnosis of the low fuel warning lamp and the instrument cluster circuitry, refer to Instrument Panel/Testing and Inspection. See: Instrument Cluster / Carrier/Testing and Inspection Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Data Link Connector As a functional test, the MIL (check engine) illuminates at key-on before engine cranking. Whenever the Powertrain Control Module (PCM) sets a Diagnostic Trouble Code (DTC) that affects vehicle emissions, it illuminates the MIL. If a problem is detected, the PCM sends a message to the instrument cluster to illuminate the lamp. The PCM illuminates the MIL only for DTC's that affect vehicle emissions. There are some monitors that may take two consecutive trips, with a detected fault, before the MIL is illuminated. The MIL stays on continuously when the PCM has entered a Limp-In mode or identified a failed emission component. Also, the MIL either flashes or illuminates continuously when the PCM detects active engine misfire. Additionally, the PCM may reset (turn off) the MIL when one of the following occur: ^ PCM does not detect the malfunction for 3 consecutive trips (except misfire and Fuel system Monitors). ^ PCM does not detect a malfunction while performing three successive engine misfire or fuel system tests. The PCM performs these tests while the engine is operating within ± 375 RPM of and within 10 % of the load of the operating condition at which the malfunction was first detected. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 6703 Malfunction Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative malfunction indicator (Check Engine) lamp condition. If the lamp comes on and stays on with the engine running, refer to Powertrain Management/Computers and Control Systems/Testing and Inspection. See: Powertrain Management/Computers and Control Systems/Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the malfunction indicator lamp falls to light during the bulb test (about two seconds after the ignition switch is turned to the On position), replace the malfunction indicator lamp bulb with a known good unit. If the indicator lamp still fails to operate, diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For further diagnosis of the malfunction indicator lamp and the instrument cluster circuitry, refer to Instrument Panel/Testing and Inspection. See: Instrument Cluster / Carrier/Testing and Inspection Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation Odometer: Description and Operation SYSTEM OPERATION The odometer and the trip odometer share the same Liquid Crystal Display (LCD) on the instrument cluster circuit board. Each gives an indication of the distance the vehicle has travelled. However, by depressing the reset knob on the face of the instrument cluster, the display mode can be switched from odometer to trip odometer. Depressing the reset knob for longer than two seconds while in the trip odometer mode will reset the trip odometer to zero. The odometer and trip odometer display values are based upon odometer and trip odometer messages received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses a speed pulse input received from the Controller Anti-lock Brake (CAB) and internal programming to decide what vehicle speed and distance messages are required. The PCM then sends the proper messages to the instrument cluster circuitry on the CCD data bus. The CAB uses an input from the rear wheel speed sensor and internal programming, which includes a programmable pinion factor to compensate for different axle gear ratios and tire sizes, to determine what speed pulse output is required. The CAB then sends the proper speed pulse to the PCM on a hard wired circuit. The instrument cluster stores both the last odometer and last trip odometer distance messages it receives from the PCM, and displays the proper value based upon ignition key-on and trip odometer reset knob inputs. If the instrument cluster stops receiving distance messages from the PCM during its current ignition key-on cycle, the odometer or trip odometer will display the last distance value that was received. If the instrument cluster has not received any distance messages from the PCM during its current ignition key-on cycle, the odometer or trip odometer display will blink. The rear wheel speed sensor is excited by an exciter ring on the differential case within the rear axle housing. Incorrect tire size, incorrect axle ratio, an incorrect pinion factor, a faulty or improperly installed rear wheel speed sensor, a faulty rear axle exciter ring, or a faulty CAB can each result in inaccurate odometer readings. For diagnosis of the odometer and trip odometer inputs, a DRB scan tool and the proper Diagnostic Procedures are recommended. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Page 6707 Odometer: Testing and Inspection If the problem being diagnosed is related to odometer and/or trip odometer accuracy, be certain to confirm that the problem is with the display and not with an incorrect pinion factor, axle ratio, or tire size. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Diagnosis of the rear wheel speed sensor and circuit, the CAB, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For further diagnosis of the odometer and/or trip odometer and the instrument cluster circuitry, refer to Instrument Panel/Testing and Inspection. See: Instrument Cluster / Carrier/Testing and Inspection Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation SYSTEM OPERATION The oil pressure gauge gives an indication of the engine oil pressure. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon engine oil pressure messages received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the engine oil pressure sensor and internal programming to decide what engine oil pressure messages are required. The PCM then sends the proper messages to the instrument cluster on the CCD data bus. If the PCM messages indicate that oil pressure is too low, the instrument cluster circuitry moves the gauge needle to the 0 PSI graduation on the gauge face, turns on the Check Gauges lamp, and sends a chime tone request to the Central Timer Module (CTM). If the PCM messages indicate that oil pressure is too high, the instrument cluster circuitry moves the gauge needle to the 110 PSI graduation on the gauge face. The engine oil pressure sensor is installed in a threaded hole that penetrates an oil passage of the engine. The engine oil pressure sensor contains a flexible diaphragm and a variable resistor coil. The diaphragm moves in response to changes in the engine oil pressure, which changes the internal electrical resistance of the sensor. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation > Page 6711 Oil Pressure Gauge: Testing and Inspection If the problem being diagnosed is related to oil pressure gauge accuracy, be certain to confirm that the problem is with the gauge and not with the engine oiling system performance. The actual engine oil pressure should be checked with a test gauge and compared to the instrument cluster oil pressure gauge readings before you proceed with gauge diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Increased oil pressure gauge needle activity may be noted with this instrument cluster than with previous designs. This increased needle activity is due to changes that were made to the instrument cluster software that are intended to make the gauge more responsive, and not due to any problem with the engine oiling or oil pressure gauge systems. No attempt at service of these systems should be made, unless the oil pressure gauge readings remain in the high end or the low end of the normal range. Diagnosis of the oil pressure sensor and circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For further diagnosis of the oil pressure gauge and the instrument cluster circuitry, see Instrument Cluster in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Transmission Wiring, Camshaft Position Connector, Distributor, Oilpressure Sending Unit/switch Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 6715 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation SYSTEM OPERATION The overdrive-off indicator lamp gives the driver an indication that the automatic transmission overdrive has been locked out. The lamp is controlled by the Powertrain Control Module (PCM) on a hard wired circuit to instrument cluster. The PCM receives an input from the momentary overdrive lockout switch, which is located on the end of the automatic transmission gearshift selector lever. The PCM uses the overdrive lockout switch input, along with numerous other sensor inputs and its internal programming to decide whether the over-drive-off indicator lamp should be on or off. The PCM then turns the lamp on or off by controlling the ground path for the lamp control circuit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 6719 Overdrive Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative overdrive-off indicator lamp condition. If the overdrive-off indicator lamp comes on and stays on with the engine running, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) and the transmission control system circuits. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Unplug the gray PCM wire harness connector. Install a jumper wire between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. Connect the battery negative cable. Turn the ignition switch to the On position. The overdrive-off indicator lamp should light. Remove the jumper wire and the lamp should turn off. If OK, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) and the transmission control system circuits. If not OK, go to Step 5. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the instrument cluster. Check for continuity between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the short circuit as required. 5. Check for continuity between the overdrive lamp driver circuit cavities of the gray PCM wire harness connector and the instrument cluster wire harness connector (connector A). There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6728 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6737 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6738 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6739 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6740 Audible Warning Device Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6741 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6742 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6743 Audible Warning Device Control Module: Electrical Diagrams 8w-45-2 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6744 8w-45-3 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6745 8w-45-4 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6746 8w-45-5 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6747 8w-45-6 NOTE: To view Diagrams referred to in these diagrams SEE Complete Body and Chassis Diagrams.. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 6748 Audible Warning Device Control Module: Description and Operation SYSTEM OPERATION A Central Timer Module (CTM) is used on this vehicle when it is equipped with the optional Vehicle Theft Security System (VTSS). In addition to serving as the security system module, the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, and a Remote Keyless Entry (RKE) module in a single unit. The CTM is also able to control and integrate many of the additional electronic functions and features included on models with this option. The CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The horn relay is one of the outputs that the CTM can control. The CTM is programmed to energize or de-energize the horn relay in response to certain inputs from the Vehicle Theft Security System (VTSS) and the Remote Keyless Entry (RKE) system. Refer to Body and Frame/Locks/Power Locks Systems for more information on the RKE system. Refer to Accessories and Optional Equipment/Antitheft and Alarm Systems/Vehicle Theft/Security Systems for more information on the VTSS. The CTM is mounted under the instrument panel, to the inboard side of the left center instrument panel support. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Central Timer Module Replacement For diagnosis of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. The CTM controls features and functions of the power lock, illuminated entry, and Remote Keyless Entry (RKE) systems. The CTM receives hard wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio frequency inputs from the RKE transmitters. In response to those and many other inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the headlamp and horn relays, and the courtesy lamps. The RKE receiver within the CTM has a memory function to retain the vehicle access codes of at least one, but no more than four RKE transmitters. The receiver is designed to retain the transmitter codes in memory, even if the battery is disconnected. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the REE transmitter. - A delay lock feature. With the delay lock feature, if a side or rear door is still open when a lock request is received by the CTM, the module will automatically cycle all of the power lock motors to lock five seconds after the doors are closed. - An enhanced accident response feature will unlock all doors, then prevent the power door lock system from locking the doors for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors and the liftgate after the vehicle reaches a speed of about 24 kilometers-per- hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. The CTM is mounted under the instrument panel, to the inboard side of the left center instrument panel support. Refer to Central Timer Module Replacement. The programmable features of the CTM can be enabled or disabled using the DRB scan tool as described in the proper Diagnostic Procedures. For diagnosis of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. A Central Timer Module (CTM) is used on this vehicle when it is equipped with the optional Vehicle Theft Security System (VTSS). In addition to serving as the security system module, the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, and a Remote Keyless Entry (RKE) module in a single unit. The CTM is also able to control and integrate many of the additional electronic functions and features included on models with this option. The CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 6749 hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. One of the features that the CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard--wired inputs from the door ajar, front door lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp (or security) relay, horn relay; and the security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS. The CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering function; of the VTSS. The CTM is mounted under the instrument panel, to the inboard side of the left center instrument panel support. Refer to Instrument Panel, Gauges and Warning Indicators/Audible Warning Device Control Module/ Central Timer Module Replacement. The programmable features of the CTM can be enabled or disabled using the DRB scan tool as described in the proper Diagnostic Procedures. For diagnosis of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 6750 Audible Warning Device Control Module: Testing and Inspection NOTE: The following tests may not prove conclusive in the diagnosis of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the CTM requires the use of a DRB scan tool. The CTM is used on models that are equipped with the optional Vehicle Theft Security System (VTSS). If the problem being diagnosed involves only the RKE horn chirp feature, see Horn Relay in the Diagnosis and Testing. If the relay checks OK; or if the problem being diagnosed involves the rolling door locks, door lock inhibit, or enhanced accident response features, further diagnosis of the CTM should be performed using a DRB scan tool. 1. Check the fused B(+) fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Check the fused ignition switch output fuse in the junction block. If OK, go to Step 5. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 4. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output fuse in the junction block. If OK, turn the ignition switch to the Off position and go to Step 6. If not OK, repair the open circuit to the ignition switch as required. 5. Disconnect and isolate the battery negative cable. Access and unplug the CTM wire harness connectors. Refer to Instrument Panel, Gauges and Warning Indicators/Audible Warning Device Control Module/Central Timer Module Replacement. 6. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 8. If not OK, repair the connections as required. 7. Probe the ground circuit cavity in the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity If OK, go to Step 9. If not OK, repair the open circuit(s) to ground as required. 8. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity in the 14-way CTM wire harness connector. If OK, go to Step 10. If not OK, repair the open circuit to the fuse in the junction block as required. 9. Probe the door lock switch output (lock) circuit cavity in the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 11. If not OK, repair the open circuit from either or both power lock switch(s) to the CTM as required. 10. Probe the door lock switch output (unlock) circuit cavity in the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 12. If not OK, repair the open circuit from either or both power lock switch(s) to the CTM as required. 11. Disconnect and isolate the battery negative cable. Reinstall the wire harness connectors to the CTM. Connect the battery negative cable. Back probe the door lock driver circuit cavity in the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 13. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 12. Still back probing the door lock driver circuit cavity in the 18-way CTM wire harness connector, open the side or rear cargo door. Move the power lock switch to the Lock position or press the Lock button of the RKE transmitter. Now close all of the doors. Within five seconds of the last door closing, there should be battery voltage on the door lock driver circuit. If OK, go to Step 14. If not OK, replace the faulty CTM. 13. Back probe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter If OK. see Power Lock Motor in the Diagnosis and Testing. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 6751 Audible Warning Device Control Module: Service and Repair A Central Timer Module (CTM) is only used on high-line versions of this vehicle that are also equipped with the Vehicle Theft Security System (VTSS). See Central Timer Module in the General information. Before replacing a CTM, use a DRB scan tool to determine the current settings for tile CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the engine cover from the passenger compartment. Central Timer Module Remove/Install 3. Remove the three screws that secure the CTM to the inboard side of the left center instrument panel support. 4. Pull the CTM away from its mounting location far enough to access and unplug the two wire harness connectors. 5. Remove the CTM from the instrument panel. 6. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). NOTE: If a new Central Timer Module is installed, the programmable features must be enabled and or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation SYSTEM OPERATION The seat belt reminder lamp gives a visual reminder to the vehicle occupants to fasten their seat belts. The lamp is turned on by the instrument cluster circuitry for about seven seconds when the ignition switch is turned to the On position. The instrument cluster also receives a hard wired input from the driver seat belt switch. However, this input only affects the chime function and has no effect on the seat belt reminder lamp operation. If the driver seat belt switch is closed (seat belt is not buckled), the instrument cluster will send a chime request to the Central Timer Module (CTM) lasting the duration of the seat belt reminder lamp illumination. The chime warning will stop when the driver seat belt switch is open (seat belt is buckled). The seat belt reminder lamp also serves as a backup for the airbag indicator lamp. About twenty seconds after the ignition switch is turned to the On position, if an inoperative airbag indicator lamp circuit was detected during the bulb test sequence, the instrument cluster circuitry will flash the seat belt reminder lamp on and off for about thirty seconds. If the seat belt reminder lamp stays on after flashing for thirty seconds, or comes on at any time other than about twenty seconds after the initial ignition-on sequence, it indicates an airbag system fault has been detected and that the airbag indicator lamp is inoperative. Refer to Air Bags and Seat Belts/Air Bags for more information on the airbag system. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation > Page 6755 Seat Belt Reminder Lamp: Testing and Inspection The diagnosis found here addresses an inoperative seat belt reminder lamp condition. If the lamp comes on and flashes following its display function (about ten seconds after the ignition switch is turned to the On position), it indicates an inoperative airbag indicator lamp. Refer to Restraint Systems/Air Bag Systems/Testing and Inspection for additional testing procedures. See: Restraint Systems/Air Bag Systems/Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the seat belt reminder lamp fails to light during its normal display function (about six seconds after the ignition switch is turned to the On position), see Instrument Cluster in the Diagnosis and Testing for further diagnosis. This lamp is completely controlled by the instrument cluster circuitry. On models equipped with a Central Timer Module, the hard wired seat belt switch input to the instrument cluster has no control over the seat belt reminder lamp function and is only used by the instrument cluster circuitry as a reference for its chime request function. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams Door Switch: Diagrams Left Front Door Ajar Switch Connector Right Front Door Ajar Switch Connector Auxiliary Door Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 6760 Auxiliary Door Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions Fuel Gauge Sender: Technical Service Bulletins Engine Controls/Fuel System - Service Manual Revisions NUMBER: 26-12-97H GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.5L, 3.9L, 5.2L, 8.0L Powertrain Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the "No Cam Signal at PCM" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page 6765 29 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page 6766 56 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page 6767 58 Revision to the "Fuel Level Sending Unit" test Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page 6768 412 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6769 Fuel Gauge Sender: Description and Operation DESCRIPTION The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a vanable resistor (track). The resistor track is used to send electrical signals to the Powertrain Control Module (PCM) for fuel gauge operation and for OBD II emission requirements. OPERATION For fuel gauge operation: As fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This increases the sending unit resistance causing the fuel gauge to read empty. After this fuel level signal is sent to the PCM, the PCM will transmit the data across the CCD bus circuits to the instrument panel. Here it is translated into the appropriate fuel gauge level reading. For OBD II emission monitor requirements: A voltage signal is sent from the resistor track on the sending unit to the PCM to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6770 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. To test the gauge sending unit only, it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal Installation for procedures. Measure the resistance across the sending unit terminals. With float in up position, resistance should be 20 ohms ± 6 ohms. - With float in down position, resistance should be 220 ± 6 ohms. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6771 Fuel Gauge Sender: Service and Repair Fig 30 Fuel Gauge Sending Unit Location The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located on top of fuel tank. REMOVAL 1. Remove fuel tank. 2. Remove fuel pump module. 3. Carefully separate the lower section of pump module from upper section by releasing three module lock tabs. Take care not to stretch plastic fuel line within module. 4. Unplug 6-way electrical connector. 5. Disconnect 2 sending unit wires at 6-way connector. Note location of wires within 6-way connector. Fig 31 Fuel Gauge Sending Lock Tab/Tracks 6. The sending unit is retained to pump module with a small lock tab and notch. Carefully pry up on lock tab to release from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 6-way connector. 4. Connect 6-way electrical connector to module. 5. Carefully connect lower section of pump module to upper section (3 tabs lock upper section to lower section). 6. Install fuel pump module. 7. Install fuel tank. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation SYSTEM OPERATION The speedometer gives an indication of the current vehicle speed. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon vehicle speed messages received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses a speed pulse input received from the Controller Anti-lock Brake (CAB) and internal programming to decide what vehicle speed and distance messages are required. The PCM then sends the proper messages to the instrument cluster circuitry on the CCD data bus. The CAB uses an input from the rear wheel speed sensor and internal programming, which includes a programmable pinion factor to compensate for different axle gear ratios and tire sizes, to determine what speed pulse output is required. The CAB then sends the proper speed pulse to the PCM on a hard wired circuit. The rear wheel speed sensor is excited by an exciter ring on the differential case within the rear axle housing. Incorrect tire size, incorrect axle ratio, an incorrect pinion factor, a faulty or improperly installed rear wheel speed sensor, a faulty rear axle exciter ring, or a faulty CAB can each result in inaccurate speedometer readings. For diagnosis of the speedometer inputs, a DRB scan tool and the proper Diagnostic Procedures are recommended. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation > Page 6775 Speedometer Head: Testing and Inspection If the problem being diagnosed is related to speedometer accuracy, be certain to confirm that the problem is with the speedometer gauge and not with an incorrect pinion factor, axle ratio, or tire size. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Diagnosis of the rear wheel speed sensor and circuit, the CAB, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For further diagnosis of the speedometer and the instrument cluster circuitry, refer to Instrument Panel/Testing and Inspection. See: Instrument Cluster / Carrier/Testing and Inspection. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation SYSTEM OPERATION The coolant temperature gauge gives an indication of the engine coolant temperature. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon engine coolant temperature messages received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the engine coolant temperature sensor and internal programming to decide what engine coolant temperature messages are required. The PCM then sends the proper messages to the instrument cluster on the CCD data bus. If the PCM messages indicate that coolant temperature is too high, the instrument cluster circuitry moves the gauge needle to the high end of the scale on the gauge face, turns on the Check Gauges lamp, and sends a chime tone request to the Central Timer Module (CTM). The engine coolant temperature sensor is installed in a threaded hole that penetrates a coolant passage of the engine. It is a thermistor-type sensor that changes its internal resistance with changes in engine coolant temperature. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Page 6779 Temperature Gauge: Testing and Inspection If the problem being diagnosed is related to coolant temperature gauge accuracy, be certain to confirm that the problem is with the gauge and not with cooling system performance. The actual engine coolant temperature should be checked with a test gauge or thermometer and compared to the instrument cluster coolant temperature gauge readings before you proceed with gauge diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Diagnosis of the coolant temperature sensor and circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For further diagnosis of the coolant temperature gauge and the instrument cluster circuitry, see Instrument Cluster in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Locations Generator, A/C Compressor, Elec.CONN, Engine Coolant Temperature Sensor Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation SYSTEM OPERATION Transmission Oil Temperature Warning Lamp The transmission oil temperature warning lamp gives an indication when the Powertrain Control Module (PCM) has detected that the automatic transmission oil is overheated. The lamp is controlled by the instrument cluster circuitry based upon messages received from the PCM on the Chrysler Collision Detection (CCD) data bus. The PCM sends lamp-on messages for about two seconds when the ignition switch is turned to the On position as a bulb test. Following the bulb test, the PCM uses an input from the automatic transmission oil temperature sensor located within the transmission, along with its internal programming, to decide whether a condition exists that requires the transmission oil temperature warning lamp to be turned on. The PCM then sends the proper messages to the instrument cluster on the CCD data bus to turn the lamp on or off. When the instrument cluster receives a message to turn the transmission oil temperature warning lamp on, it also sends a chime tone request to the Central Timer Module (CTM). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Page 6786 Temperature Warning Lamp/Indicator: Testing and Inspection Transmission Oil Temperature Warning Lamp The diagnosis found here addresses an inoperative transmission oil temperature warning lamp condition. If the transmission oil temperature warning lamp comes on and stays on with the engine running. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the transmission oil temperature warning lamp fails to light during the bulb test (about two seconds after the ignition switch is turned to the On position), diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For further diagnosis of the transmission oil temperature warning lamp and the instrument cluster circuitry, see Instrument Cluster in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Description and Operation Transmission Shift Position Indicator Lamp: Description and Operation SYSTEM OPERATION The gear selector indicator gives an indication of the position of the automatic transmission gear selector lever. The indicator is mounted to the rear of the instrument cluster housing. The indicator is mechanically actuated by a cable connected to the gear selector indicator driver lever of the gear selector lever mechanism on the steering column. This covers only the removal and installation of the gear selector indicator. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Description and Operation > Page 6790 Transmission Shift Position Indicator Lamp: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster from the instrument panel. See instrument Cluster Replacement for the procedures. Gear Selector Indicator Remove/Install 3. Remove the two screws that secure the gear selector indicator mechanism to the rear of the instrument cluster housing. 4. Remove the gear selector indicator mechanism from the cluster housing. 5. Place the gear selector lever on the steering column in the Park position. 6. Remove the knee blocker from the instrument panel. See Knee Blocker Replacement for the procedures. Gear Selector Indicator Cable Remove/Install 7. Squeeze the latches on the gear selector indicator cable housing retainer and pull the retainer out of the receptacle on the PRNDL adjuster, located on the right side of the steering column near the shift lever actuator. 8. Guide the gear selector indicator cable out of the PRNDL adjuster through the slot in the receptacle. 9. Disengage the loop end of the gear selector indicator cable from the hook on the shift lever actuator. 10. Remove the gear selector indicator from the instrument panel. 11. Reverse the removal procedures to install. Tighten the gear selector indicator mounting screws to 2.2 N.m (20 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation Volt Meter Gauge: Description and Operation SYSTEM OPERATION The voltmeter gives an indication of the electrical system voltage. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon system voltage messages received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the electrical system and internal programming to decide what system voltage messages are required. The PCM then sends the proper messages to the instrument cluster on the CCD data bus. If the PCM messages indicate that the charging system has failed, the electrical system voltage is less than 11 volts or greater than 16.6 volts, the instrument cluster circuitry turns on the Check Gauges lamp and sends a chime tone request to the Central Timer Module (CTM). Refer to Starting and Charging/Charging Systems for more information on the charging system components and their diagnosis. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation > Page 6794 Volt Meter Gauge: Testing and Inspection If the problem being diagnosed is related to voltmeter gauge accuracy, be certain to confirm proper charging system operation before considering instrument cluster replacement. Refer to Starting and Charging/Charging System for more information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Diagnosis of the system voltage input circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For further diagnosis of the voltmeter and the instrument cluster circuitry, refer to Instrument Panel/Testing and Inspection. See: Instrument Cluster / Carrier/Testing and Inspection Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service and Repair Backup Light Bulb: Service and Repair REMOVAL 1. Remove the screws attaching the lamp to the vehicle. Bulb Socket Removal 2. Rotate the bulb socket 1/4 turn counterclockwise to remove it from the housing. 3. Pull the bulb straight out of the socket to remove it. INSTALLATION 1. Press bulb into socket and position socket in housing. 2. Rotate the bulb socket 1/4 turn clock-wise to install in the housing. 3. Position the lamp on the vehicle and install screws. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Lamp Switch Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6803 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > General Information Brake Light Switch: Description and Operation General Information SYSTEM OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is mounted on the brake pedal mounting bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > General Information > Page 6806 Brake Light Switch: Description and Operation Switch With RWAL System The primary function of the switch,is to turn on the stop lamps during braking. The switch is also used to send signals to components that must know when the brakes are applied, such as the Powertrain Control Module (PCM), which uses the signal to cancel speed control. The Controller Antilock Brake (CAB) uses the brake switch signal to monitor brake pedal application. When the switch contacts open (brakes applied), the CAB receives the brake applied signal. The CAB then monitors the ABS system to anticipate the need for an ABS stop. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6807 Brake Light Switch: Testing and Inspection GENERAL INFORMATION Stop lamp switch operation can be tested with an ohmmeter. The ohmmeter is used to check continuity between the pin terminals at different plunger positions. NOTE: The switch wire harness must be disconnected before testing switch continuity. SWITCH CIRCUIT IDENTIFICATION Stop Lamp Switch Terminal Identification - Terminals 1 and 2 are for the RWAL/ABS module and Powertrain Control Module (PCM) circuit. - Terminals 5 and 6 are for the stop lamp circuit. - Terminals 3 and 4 are for the speed control circuit. SWITCH CONTINUITY TEST 1. Check continuity between terminal pins 5 and 6 as follows: a. Pull plunger all the way out to fully extended position. b. Attach test leads to pins 5 and 6 and note ohmmeter reading. c. If continuity exists, proceed to next test. Replace switch if meter indicates lack of continuity (shorted or open). 2. Check continuity between terminal pins 1 and 2 and pins 3 and 4 as follows: a. Push switch plunger inward to fully retracted position. b. Attach test leads to pins 1 and 2 and note ohmmeter reading. c. If continuity exists, switch is OK. Replace switch if meter indicates lack of continuity (switch is open). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6808 Brake Light Switch: Adjustments The switch can be adjusted by lightly pulling the brake pedal rearward against the internal booster stop. This will set the switch plunger to the proper position. CAUTION: Do not use excessive force to pull the pedal rearward. Excessive force will damage switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6809 Brake Light Switch: Service and Repair REMOVAL 1. Remove lower column cover. 2. Remove the Data Link Connector, hood release lever and park brake release lever from the knee blocker. 3. Remove the knee blocker for access to switch. 4. Press and hold brake pedal in applied position. Stop Lamp Switch Mounting 5. Rotate stop lamp switch counterclockwise about 1/16 turn to unlock switch. Then pull switch straight out of mounting bracket and release brake pedal. 6. If switch is to be tested or replaced, disconnect wire harness and remove switch from vehicle. INSTALLATION 1. Pull switch plunger all the way out. Then push plunger 4 notches inward to preset position. Plunger length out of housing will be approximately 14 mm (0.55 inch). 2. Plug wire harness connector into switch. 3. Press and hold brake pedal in applied position. 4. Align switch locking collar index in switch bracket. Then insert switch straight into bracket. 5. Turn switch clockwise about 1/16 turn to lock it in position. 6. Release brake pedal. 7. Lightly pull brake pedal rearward against internal stop in booster. CAUTION: Do not use excessive force to move the pedal rearward for switch adjustment. Excessive force will damage the switch. 8. Install the knee blocker. 9. Install the Data Link Connector, hood release lever and park brake release lever to the knee blocker. 10. Install lower column cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Dome/Cargo Lamp Cargo Lamp: Service and Repair Dome/Cargo Lamp REMOVE 1. Using a small flat blade, pry lens from lamp bezel. Dome/Cargo Lamp 2. Remove screws attaching lamp bezel to roof crossmember mounting brackets. 3. Detach bulb socket tabs from lamp bezel. 4. Remove lamp bezel. INSTALLATION 1. Position lamp bezel in headliner opening. 2. Insert bulb socket tabs in lamp bezel. 3. Align lamp bezel with roof crossmember mounting brackets and install screws. 4. Install the lamp lens. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Dome/Cargo Lamp > Page 6814 Cargo Lamp: Service and Repair Dome/Cargo Lamp Bulb REMOVAL 1. Remove lamp lens. 2. Pull bulb down to remove from socket. INSTALLATION 1. Push bulb into socket. 2. Install lamp lens. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair Center Mounted Brake Lamp Bulb: Service and Repair REMOVAL 1. Remove the two screws holding the lamp assembly to the housing. 2. Pull the lamp straight out from the roof panel. 3. To remove a bulb socket, turn it counterclockwise and pull out. CHMSL Bulb Removal 4. Pull the bulb from the socket. INSTALLATION 1. Position bulb in socket and turn clock-wise. 2. Position lamp on vehicle and install screws. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Reach through and above the instrument panel glove box opening upper reinforcement to depress the retaining tabs on the top and bottom of the glove box lamp and switch housing. Glove Box Lamp And Switch Remove/Install 4. While holding the retaining tabs depressed, push the glove box lamp and switch unit out through the hole in the mounting tab on the upper instrument panel glove box opening. 5. Pull the glove box lamp and switch out through the mounting tab far enough to access and unplug the two wire harness connectors. 6. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Diagrams Courtesy Lamp Defeat Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Service and Repair Daytime Running Lamp Control Unit: Service and Repair Daytime Running Light Module The headlamps on vehicles sold in Canada will illuminate when the vehicle is started. The lamps illuminate at less than 50% of normal intensity. To disable the DRLM, set park bake. REMOVAL The Daytime Running Light Module (DRLM) is mounted in the engine compartment on the bottom of the cowl plenum next to the windshield wiper motor. 1. Remove the bolts holding the (DRLM) and bracket to the vehicle. 2. Disconnect the electrical connector. INSTALLATION 1. Connect the electrical connector. 2. Install the bolts holding the (DRLM) and bracket to the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair Dome Lamp Bulb: Service and Repair Dome Lamp Bulb REMOVAL 1. Using a small flat blade, pry the left side (driver's side) of the lamp lens downward. 2. Pull bulb from lamp. INSTALLATION 1. Install bulb in lamp. 2. Position lens on lamp and snap into place. Dome/Cargo Lamp Bulb REMOVAL 1. Remove lamp lens. 2. Pull bulb down to remove from socket. INSTALLATION 1. Push bulb into socket. 2. Install lamp lens. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams Door Switch: Diagrams Left Front Door Ajar Switch Connector Right Front Door Ajar Switch Connector Auxiliary Door Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 6837 Auxiliary Door Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation Hazard Warning Flasher: Description and Operation SYSTEM OPERATION The combination flasher is a smart relay that functions as both the turn signal system and hazard warning system flasher. The combination flasher contains active electronic Integrated Circuitry (IC) elements. This flasher is designed to handle the current flow requirements of the factory-installed lighting. If supplemental lighting is added to the turn signal lamp circuits, such as when towing a trailer with lights, the combination flasher will automatically try to compensate to keep the flash rate the same. While the combination flasher has a International Standards Organization (ISO)-type relay terminal configuration or footprint, the internal circuitry is much different. The combination flasher does not use standard 150-relay inputs or provide ISO-relay type outputs or functions. The combination flasher should never be substituted for an ISO-relay or replaced with an ISO-relay, or else component and vehicle damage may occur. Combination Flasher - Typical The combination flasher has five blade-type terminals intended for the following inputs and outputs: Battery B+, Ignition B+, Ground, Turn Signal circuit, and Hazard Warning circuit. Constant battery voltage and ground are supplied to the flasher so that it can perform the hazard warning function, and ignition switched battery voltage is supplied for the turn signal function. The IC within the combination flasher contains the logic that controls the flasher operation and the flash rate. Pin 6 of the IC receives a sense voltage from the hazard warning portion of the multi-function switch. When the hazard switch is turned on, the "hazard on sense" voltage will become low due to the circuit being grounded through the turn signal bulbs. This low voltage sense signals the IC to energize the flash control Positive-Negative-Positive (PNP) transistor at a pre-calibrated flash rate or frequency Each time the PNP transistor energizes the hazard warning circuit, the pin 6 "hazard on sense" voltage will become high and the IC signals the PNP transistor to de-energize the circuit. This cycling will continue until the hazard warning switch is turned off. Likewise, pin 8 of the IC receives a sense voltage from the turn signal portion of the multi-function switch. When the left or right turn signal is turned on, the "turn signal on sense" voltage will become low due to the circuit being grounded through the turn signal bulbs. This low voltage sense signals the IC to energize the flash control PNP transistor at a precalibrated flash rate or frequency. Each time the PNP transistor energizes the turn signal circuit, the pin 8 "turn signal on sense" voltage will become high and the IC signals the PNP transistor to de-energize the circuit. This cycling will continue until the right or left turn signal is turned off. A special design feature of the combination flasher allows it to "sense" that a turn signal circuit or bulb is not operating, and provide the driver an indication of the condition by flashing the remaining bulbs in the affected circuit at a higher rate (120 flashes-per-minute or higher). Conventional flashers either continue flashing at their typical rate (heavy-duty type), or discontinue flashing the affected circuit entirely (standard-duty type). During turn signal operation, the combination flasher IC compares normal battery voltage input on pin 2 with the shunt resistor voltage input on pin 7. If the IC "senses" that the voltage difference between pin 2 and pin 7 is different than the pre-calibrated value of the IC, it will increase the rate at which it signals the PNP transistor to energize the pin 1 output. Thus, the inoperative half (left or right side) of the turn signal circuit will flash faster. Because of the active electronic elements within the combination flasher, it cannot be tested with conventional automotive electrical test equipment. If the combination flasher is believed to be faulty; test the turn signal and hazard warning system circuits as described. Then replace the combination flasher with a known good unit to confirm system operation. The combination flasher cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Page 6842 Hazard Warning Flasher: Service and Repair REMOVAL AND INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the end cap from the driver side end of the instrument panel. Refer to Instrument Panel Gauges and Warning Systems/Instrument Panel/Instrument Panel End Cap Replacement. Junction Block 3. Unplug the combination flasher from the junction block. 4. Install the combination flasher by aligning the flasher terminals with the cavities in the junction block and pushing the flasher firmly into place. 5. Connect the battery negative cable. 6. Test the flasher operation. 7. Reinstall the end cap on the instrument panel. Refer to Instrument Panel Gauges and Warning Systems/Instrument Panel/Instrument Panel End Cap Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation Hazard Warning Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch assembly, which is secured to the left side of the steering column. A switch stalk that extends from the left side of the multi-function switch is moved up or down to activate the right or left turn signals, respectively A latching push-button that extends upward from the multi-function switch and through the top of the upper steering column shroud is used to control the hazard warning system. The multi-function switch also contains circuitry for the following functions: Headlamp beam selection - Headlamp optical horn - Horn contact and circuit - Windshield wipers - Windshield washers. The information contained addresses only the multi-function switch turn signal and hazard warning switches. For information relative to the other circuits and switches that are integral to the multi-function switch. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit of the multi-function switch is faulty or damaged, the entire multi-function switch assembly must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation > Page 6846 Hazard Warning Switch: Testing and Inspection The turn signal switch and the hazard warning switch are integral to the multi-function switch. See Turn Signal and Hazard Warning Systems in the Diagnosis and Testing before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Unplug the steering column wire harness connector. Turn Signal Switch And Hazard Warning Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the steering column half of the steering column wire harness connector terminals as shown in the Turn Signal Switch and Hazard Warning Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, repair the open circuit in the steering column wire harness or replace the faulty multi-function switch assembly as required. If the switches are OK, repair the lighting circuits as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation > Page 6847 Hazard Warning Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. Refer to Airbag Module in the Removal and Installation for the procedures. 3. if the vehicle is equipped with the optional vehicle speed control, unplug the wire harness connectors from the speed control switches in the steering wheel. 4. Remove the nut that secures the steering wheel to the steering column upper shaft. 5. Remove the steering wheel with a steering wheel puller (Special Tool C-3428-B). 6. Remove the knee blocker from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Knee Diverter/Knee Blocker Replacement. 7. If the vehicle is so equipped, remove the tilt steering column lever by grasping the lever firmly and pulling it sharply away from the column. Lower Steering Column Shroud Screws 8. Remove the two screws from the bottom of the lower steering column shroud that secure it to the upper shroud. 9. Unsnap the front and both sides of the lower shroud from the upper shroud. Lower Steering Column Shroud Remove/Install 10. Tilt the lower shroud downward and slide it back to disengage the hooks from the pivots on the upper shroud. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation > Page 6848 Upper Steering Column Shroud Remove/Install 11. Remove the two screws that secure the upper shroud to the steering column. 12. Remove the upper shroud from the steering column. Steering Column Tie-Wraps 13. Remove the two lower wire harness tie wraps. 14. Remove the screw from the center of the steering column wire harness connector and unplug the two halves of the connector. 15. Disengage the two multi-function switch wire harness connectors (one 17-way and one 13-way) from the steering column wire harness insulator. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation > Page 6849 Multi-Function Switch Remove/Install 16. Remove the two screws that secure the multi-function switch to the steering column. 17. Remove the multi-function switch from the steering column. 18. Reverse the removal procedures to install. During installation, check that the following procedures are accomplished: - Tighten the multi-function switch mounting screws to 6 N.m (53 in. lbs.). - Be certain that the new wire harness tie-wraps are installed in the same positions as those that were removed. - Be certain that the steering column wire harnesses are routed so that they will not be pinched or stretched. - Be certain that the upper shroud spacer mounting stud is fully seated to the mounting boss on the inside of the shroud. - Tighten the upper shroud mounting screws to 1.4 N.m (12 in. lbs.). - Tighten the lower shroud mounting screws to 3.4 N.m (30 in. lbs.). - Be certain to index the alignment splines in the hub of the steering wheel with the splines on the upper steering column shaft. - Be certain to route the wire harnesses from the clockspring between the steering wheel back trim cover and the steering wheel armature. - Tighten the steering wheel nut to 61 N.m (45 ft. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair REMOVAL 1. Raise the hood and position the support rod. Headlamp Assembly Removal 2. Press in and pull up on the headlamp release lever to remove the headlight module. Headlamp Housing And Bulb Removal 3. Pull the headlamp assembly out of headlamp mounting adaptor. 4. Disconnect wire connector from bulb. 5. Turn the bulb locking ring 1/4 turn counterclockwise and pull back on the ring to release it. 6 Pull the halogen bulb out of the headlamp housing and remove the retaining ring. INSTALLATION CAUTION: Do not touch the bulb glass. Oil from the technicians hands or other sources, such as oily shop towels, will reduce the operating time of the bulb. 1. Install lock ring over the new Halogen bulb. 2. Connect wire connector. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 6854 Headlamp Bulb Installation 3. Insert the bulb into the headlamp housing 4. turn Lock ring 1/4 turn clock wise to secure bulb 5. Install headlamp. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams VTSS Headlamp Relay Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Page 6858 Headlamp Relay: Description and Operation SYSTEM OPERATION The headlamp (or security) relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The headlamp relay is a electromechanical device that switches battery current to the headlamps when the high-line Central Timer Module (CTM) grounds the relay coil. See Headlamp Relay in the Diagnosis and Testing for more information. The headlamp relay is located in a connector that is taped back to the headlamp switch takeout of the instrument panel wire harness in the passenger compartment. To service the headlamp relay remove the headlamp switch mounting screws and pull the switch and wire harness out from the instrument panel far enough to access the relay and connector. The headlamp relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Page 6859 Headlamp Relay: Service and Repair REMOVAL AND INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Headlamp Relay Remove/Install 1. Disconnect and isolate the battery negative cable. 2. Remove the headlamp switch from the instrument panel, but do not unplug the wire harness connectors. Refer to Lighting and Horns/Headlamp Switch Replacement. 3. Pull the headlamp switch out from the instrument panel far enough to access the headlamp relay, which is taped to the headlamp switch takeout of the instrument panel wire harness. 4. Remove the tape that secures the headlamp relay and its connector to the wire harness. 5. Unplug the headlamp relay from its wire harness connector. 6. Install the headlamp relay by aligning the relay terminals with the cavities in the wire harness connector and pushing the relay firmly into place. 7. Tape the headlamp relay and its connector back to the wire harness. 8. Reinstall the headlamp switch in the instrument panel. Refer to Lighting and Horns/Headlamp Switch Replacement. 9. Connect the battery negative cable. 10. Test the relay operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Headlamp Switch Connector Headlamp Switch Ground Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 6863 Headlamp Switch: Testing and Inspection Headlamp Diagnosis When a vehicle experiences problems with the headlamp system, verify the condition of the battery connections, charging system, headlamp bulbs, wire connectors, relay, high beam dimmer switch and headlamp switch. Always begin any diagnosis by testing all of the fuses and circuit breakers in the system. Conventional and halogen headlamps are interchangeable. It is recommended that they not be intermixed on a given vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 6864 Headlamp Switch: Service and Repair WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - IF THE HEADLAMP SWITCH WAS ON, WAIT FIVE MINUTES TO ALLOW THE CERAMIC DIMMER RESISTOR TO COOL. IF THE CERAMIC DIMMER RESISTOR IS NOT ALLOWED TO COOL, IT CAN BURN YOUR FINGERS. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. See Cluster Bezel Replacement for the procedures. 3. Remove the three screws that secure the headlamp switch bezel to the instrument panel. Headlamp Switch And Bezel Remove/Install 4. Pull the headlamp switch and bezel out from the instrument panel far enough to access and unplug the wire harness connectors. 5. Pull the headlamp switch control knob out to the On position stop. 6. Depress the headlamp switch knob and shaft release button on the top of the switch. 7. While holding the release button depressed, pull the knob and shaft out of the headlamp switch. 8. Remove the spanner nut that secures the headlamp switch bezel and mounting bracket to the switch. 9. Remove the headlamp switch bezel and mounting bracket from the switch. 10. Reverse the removal procedures to install. Tighten the headlamp switch and bezel mounting screws to 2.2 N.m (20 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation Hi-Beam Indicator Lamp: Description and Operation SYSTEM OPERATION The headlamp high beam indicator lamp gives an indication when the headlamp high beams are turned on. The lamp is controlled by a hard wired input from the headlamp dimmer (multi-function) switch. One side of the high beam indicator lamp bulb is grounded at all times. The other side of the bulb receives a battery feed through the contacts of the dimmer switch when the multi-function switch stalk is actuated to turn on the headlamp high beams. Refer to Lighting and Horns/Lamps for more information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation > Page 6868 Hi-Beam Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative headlamp high beam indicator lamp condition. If the problem being diagnosed is related to inoperative headlamp high beams, refer to Lighting and Horns/Lamps for diagnosis of the headlamp system. If no headlamp system problems are found, the following procedure will help locate an open in the high beam indicator lamp circuit. For circuit descriptions and diagrams. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the instrument cluster. 2. Connect the battery negative cable.Turn the headlamps on and select the high beams with the multi-function switch stalk. Check for battery voltage at the high beam indicator driver circuit cavity of the instrument cluster wire harness connector (connector B). If OK, replace the faulty bulb. If not OK, repair the open circuit to the splice in the dimmer switch high beam output circuit of the headlamp and dash wire harness as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Description and Operation Horn Relay: Description and Operation SYSTEM OPERATION The horn relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The horn relay is a electromechanical device that switches battery current to the horn when the horn switch grounds the relay coil. See Horn Relay in the Diagnosis and Testing for more information. The horn relay is located in the junction block, which is located on the driver side end of the instrument panel in the passenger compaftment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the junction block until further diagnosis is completed. The horn relay cannot be repaired and, if faulty or damaged, it must be replaced. The horn relay is a component of the Remote Key-less Entry (RKE) system only on vehicles equipped with the optional Vehicle Theft Security System (VTSS). The horn relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The horn relay is a electromechanical device that switches battery current to the horn when the horn switch or the Central Timer Module (CTM) grounds the relay coil. See Horn Relay in the Diagnosis and Testing for more information. The horn relay is located in the junction block, which is located on the driver side end of the instrument panel in the passenger compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the junction block until further diagnosis is completed. The horn relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Description and Operation > Page 6873 Horn Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Test Horn Relay The horn relay is located in the junction block in the passenger compartment. Remove the horn relay from the junction block to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. if OK, go to Step 3. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 electromagnet. should be 75 - 5 Ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity 30. is connected to battery voltage and should be hot at all times. If OK, go to Step 3. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal 87A. is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 4. 3. The relay normally open terminal 87. is connected to the common feed terminal 30. in the energized position. This terminal supplies battery voltage to the horns. There should be continuity between the cavity for relay terminal 87 and the horn relay output circuit cavity of each horn wire harness connector at all times. If OK, go to Step 5. If not OK, repair the open circuit to the horns. as required. 4. The coil battery terminal 86. is connected to the electromagnet in the relay. It is connected to battery voltage and should be hot at all times. Check for battery voltage at the cavity for relay terminal 86. If OK, go to Step 6. If not OK, repair the open circuit to the fuse in the PDC as required. 5. The coil ground terminal 85. is connected to the electromagnet in the relay It is grounded through the horn switch when the horn switch is depressed. On vehicles equipped with the Vehicle Theft Security System VTSS., the horn relay coil ground terminal can also be grounded by the Central Timer Module CTM. in response to certain inputs related to the VTSS or Remote Keyless Entry (RKE). system. Check for continuity to ground at the cavity for relay terminal 85. There should be continuity with the horn switch depressed, and no continuity with the horn switch released. If not OK, see Horn Switch in the Diagnosis and Testing. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The horn relay is located in the junction block in the passenger compartment. Remove the horn relay from the junction block to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay circuits. If not OK, replace the faulty relay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Description and Operation > Page 6874 Horn Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the end cap from the driver side end of the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel End Cap Replacement. Junction Block 3. Unplug the horn relay from the junction block. 4. Install the horn relay by aligning the relay terminals with the cavities in the junction block and pushing the relay firmly into place. 5. Connect the battery negative cable. 6. Test the relay operation. 7. Reinstall the end cap on the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel End Cap Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations Horn Switch: Locations A center-blow, resistive membrane-type horn switch is installed on the back side of the driver side airbag module trim cover in the center of the steering wheel. When the center area of the airbag trim cover is depressed, the horn switch completes a curcuit to ground for the coil side of the horn relay. The steering wheel and steering column must be properly grounded for the horn switch to function. The horn switch is only serviced as a part of the airbag module trim cover. If the horn switch should fail, or if the airbag is deployed, the airbag module trim cover and horn switch must be replaced as a unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 6878 Horn Switch: Description and Operation SYSTEM OPERATION A center-blow, resistive membrane-type horn switch is installed on the back side of the driver side airbag module trim cover in the center of the steering wheel. When the center area of the airbag trim cover is depressed, the horn switch completes a circuit to ground for the coil side of the horn relay. The steering wheel and steering column must be properly grounded for the horn switch to function. The horn switch is only serviced as a part of the airbag module trim cover. If the horn switch should fail, or if the airbag is deployed, the airbag module trim cover and horn switch must be replaced as a unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 6879 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover and knee blocker from the instrument panel. 2. Check for continuity between the metal steering column jacket and a good ground. There should be continuity. If OK, go to Step 4. If not OK, refer to Steering and Suspension/Steering Column. 3. Remove the driver side airbag module from the steering wheel. Refer to Airbag Module in Air Bags and Seat Belts/Air Bags for the procedures. Unplug the horn switch wire harness connector from the air-bag module. 4. Unplug the horn relay from the junction block. Check for continuity between the steering column half of the horn switch feed wire harness connector and a good ground. There should be no continuity If OK, go to Step 6. If not OK, see Horn Contact in the Diagnosis and Testing. 5. Check for continuity between the steering column half of the horn switch feed wire harness connector and the horn relay control circuit cavity for the horn relay in the PDC. There should be continuity If OK, go to Step 7. If not OK, see Horn Tower in the Diagnosis and Testing. 6. Check for continuity between the horn switch feed wire and the horn switch ground wire on the airbag module. There should be no continuity. If OK, go to Step 8. If not OK, replace the faulty horn switch. 7. Depress the center of the airbag module trim cover and check for continuity between the horn switch feed wire and the horn switch ground wire on the airbag module. There should now be continuity If not OK, replace the faulty horn switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair > Driver Side Airbag Trim Cover and Horn Switch Horn Switch: Service and Repair Driver Side Airbag Trim Cover and Horn Switch REMOVAL WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE HORN SWITCH IS INTEGRAL TO THE AIRBAG MODULE TRIM COVER. SERVICE OF THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the driver side airbag module from the steering wheel. See Airbag Module - Driver Side in the Replacement. Airbag Trim Cover Retainer Nuts Remove/Install 3. Remove the four nuts that secure the upper and lower trim cover retainers to the studs on the airbag housing. Airbag Trim Cover Retainers Remove/Install 4. Remove the upper and lower trim cover retainers from the airbag housing studs. 5. Remove the horn switch ground wire eyelet from the airbag housing stud. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair > Driver Side Airbag Trim Cover and Horn Switch > Page 6882 Airbag Trim Cover Remove/Install 6. Disengage the six trim cover locking blocks from the lip around the outside edge of the airbag housing and remove the housing from the cover. WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE DRIVER SIDE AIRBAG MODULE TRIM COVER AND THE DRIVER SIDE AIRBAG MODULE. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. 7. When installing the trim cover and horn switch, be certain that the locking blocks are fully engaged on the lip of the airbag housing. Driver Side Airbag Trim Cover Locking Blocks Engaged 8. When installing the upper and lower trim cover retainers, be certain that the tabs on each retainer are engaged in the retainer slots of the trim cover. 9. Install and tighten the trim cover retainer nuts to 10 N.m (90 in. lbs.). 10. Reverse the remaining removal procedures to complete the installation, but do not connect the battery negative cable at this time. See Airbag System in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair > Driver Side Airbag Trim Cover and Horn Switch > Page 6883 Horn Switch: Service and Repair Horn Switch REMOVAL AND INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH A DRIVER SIDE AIRBAG, THE HORN SWITCH IS INTEGRAL TO THE AIRBAG MODULE TRIM COVER. SERVICE OF THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REFER TO DRIVER SIDE AIR-BAG TRIM COVER AND HORN SWITCH IN THE REMOVAL AND INSTALLATION SECTION OF AIRBAG FOR THE SERVICE PROCEDURES . Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair License Plate Bulb: Service and Repair REMOVAL - Base And Standard Bumper 1. Remove license plate. 2. Remove lamp. 3. Remove screws attaching lamp lens to housing. 4. Twist out bulb. INSTALLATION - Base And Standard Bumper 1. Install bulb in socket. 2. Install screws attaching lamp lens to housing. 3. Install lamp. 4. Install license plate. REMOVAL - Step Bumper 1. Remove lamp. 2. Remove bulb. INSTALLATION - Step Bumper 1. Install bulb. 2. Position lamp in bumper. 3. Install lamp. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair Map Light Bulb: Service and Repair REMOVAL 1. Using a small flatblade, carefully pry middle of lamp lens away from lamp. 2. Pull reflector from lamp. 3. Push bulb rearward and twist slightly to disengage wire attaching one end of bulb from terminal. 4. Separate bulb from lamp. INSTALLATION 1. Position bulb in lamp and engage bulb wire with lamp terminal. 2. Install reflector. 3. Position lens on bezel and snap into place. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair Marker Lamp Bulb: Service and Repair REMOVAL 1. Raise hood and position support rod. 2. Remove the screws from the sidemarker and turn signal lamp housing and pull out to disengage the outboard pin clip to remove the housing. Sidemarker And Turn Signal Bulb Removal 3. To remove the bulb, twist the it 1/4 turn counterclock-wise and remove it from the housing 4. Pull the bulb straight out of the socket. INSTALLATION 1. Push the replacement bulb into the socket. 2. Position the bulb in the housing and twist it 1/4 turn clock-wise. 3. Align the outboard pin clip and position the housing on the vehicle. Install the screws. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Service and Repair Daytime Running Lamp Control Unit: Service and Repair Daytime Running Light Module The headlamps on vehicles sold in Canada will illuminate when the vehicle is started. The lamps illuminate at less than 50% of normal intensity. To disable the DRLM, set park bake. REMOVAL The Daytime Running Light Module (DRLM) is mounted in the engine compartment on the bottom of the cowl plenum next to the windshield wiper motor. 1. Remove the bolts holding the (DRLM) and bracket to the vehicle. 2. Disconnect the electrical connector. INSTALLATION 1. Connect the electrical connector. 2. Install the bolts holding the (DRLM) and bracket to the vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams VTSS Headlamp Relay Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Page 6903 Headlamp Relay: Description and Operation SYSTEM OPERATION The headlamp (or security) relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The headlamp relay is a electromechanical device that switches battery current to the headlamps when the high-line Central Timer Module (CTM) grounds the relay coil. See Headlamp Relay in the Diagnosis and Testing for more information. The headlamp relay is located in a connector that is taped back to the headlamp switch takeout of the instrument panel wire harness in the passenger compartment. To service the headlamp relay remove the headlamp switch mounting screws and pull the switch and wire harness out from the instrument panel far enough to access the relay and connector. The headlamp relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Page 6904 Headlamp Relay: Service and Repair REMOVAL AND INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Headlamp Relay Remove/Install 1. Disconnect and isolate the battery negative cable. 2. Remove the headlamp switch from the instrument panel, but do not unplug the wire harness connectors. Refer to Lighting and Horns/Headlamp Switch Replacement. 3. Pull the headlamp switch out from the instrument panel far enough to access the headlamp relay, which is taped to the headlamp switch takeout of the instrument panel wire harness. 4. Remove the tape that secures the headlamp relay and its connector to the wire harness. 5. Unplug the headlamp relay from its wire harness connector. 6. Install the headlamp relay by aligning the relay terminals with the cavities in the wire harness connector and pushing the relay firmly into place. 7. Tape the headlamp relay and its connector back to the wire harness. 8. Reinstall the headlamp switch in the instrument panel. Refer to Lighting and Horns/Headlamp Switch Replacement. 9. Connect the battery negative cable. 10. Test the relay operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Description and Operation Horn Relay: Description and Operation SYSTEM OPERATION The horn relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The horn relay is a electromechanical device that switches battery current to the horn when the horn switch grounds the relay coil. See Horn Relay in the Diagnosis and Testing for more information. The horn relay is located in the junction block, which is located on the driver side end of the instrument panel in the passenger compaftment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the junction block until further diagnosis is completed. The horn relay cannot be repaired and, if faulty or damaged, it must be replaced. The horn relay is a component of the Remote Key-less Entry (RKE) system only on vehicles equipped with the optional Vehicle Theft Security System (VTSS). The horn relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The horn relay is a electromechanical device that switches battery current to the horn when the horn switch or the Central Timer Module (CTM) grounds the relay coil. See Horn Relay in the Diagnosis and Testing for more information. The horn relay is located in the junction block, which is located on the driver side end of the instrument panel in the passenger compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the junction block until further diagnosis is completed. The horn relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Description and Operation > Page 6908 Horn Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Test Horn Relay The horn relay is located in the junction block in the passenger compartment. Remove the horn relay from the junction block to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. if OK, go to Step 3. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 electromagnet. should be 75 - 5 Ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity 30. is connected to battery voltage and should be hot at all times. If OK, go to Step 3. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal 87A. is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 4. 3. The relay normally open terminal 87. is connected to the common feed terminal 30. in the energized position. This terminal supplies battery voltage to the horns. There should be continuity between the cavity for relay terminal 87 and the horn relay output circuit cavity of each horn wire harness connector at all times. If OK, go to Step 5. If not OK, repair the open circuit to the horns. as required. 4. The coil battery terminal 86. is connected to the electromagnet in the relay. It is connected to battery voltage and should be hot at all times. Check for battery voltage at the cavity for relay terminal 86. If OK, go to Step 6. If not OK, repair the open circuit to the fuse in the PDC as required. 5. The coil ground terminal 85. is connected to the electromagnet in the relay It is grounded through the horn switch when the horn switch is depressed. On vehicles equipped with the Vehicle Theft Security System VTSS., the horn relay coil ground terminal can also be grounded by the Central Timer Module CTM. in response to certain inputs related to the VTSS or Remote Keyless Entry (RKE). system. Check for continuity to ground at the cavity for relay terminal 85. There should be continuity with the horn switch depressed, and no continuity with the horn switch released. If not OK, see Horn Switch in the Diagnosis and Testing. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The horn relay is located in the junction block in the passenger compartment. Remove the horn relay from the junction block to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay circuits. If not OK, replace the faulty relay. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Description and Operation > Page 6909 Horn Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the end cap from the driver side end of the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel End Cap Replacement. Junction Block 3. Unplug the horn relay from the junction block. 4. Install the horn relay by aligning the relay terminals with the cavities in the junction block and pushing the relay firmly into place. 5. Connect the battery negative cable. 6. Test the relay operation. 7. Reinstall the end cap on the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel End Cap Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Lamp Switch Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6914 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > General Information Brake Light Switch: Description and Operation General Information SYSTEM OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is mounted on the brake pedal mounting bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > General Information > Page 6917 Brake Light Switch: Description and Operation Switch With RWAL System The primary function of the switch,is to turn on the stop lamps during braking. The switch is also used to send signals to components that must know when the brakes are applied, such as the Powertrain Control Module (PCM), which uses the signal to cancel speed control. The Controller Antilock Brake (CAB) uses the brake switch signal to monitor brake pedal application. When the switch contacts open (brakes applied), the CAB receives the brake applied signal. The CAB then monitors the ABS system to anticipate the need for an ABS stop. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6918 Brake Light Switch: Testing and Inspection GENERAL INFORMATION Stop lamp switch operation can be tested with an ohmmeter. The ohmmeter is used to check continuity between the pin terminals at different plunger positions. NOTE: The switch wire harness must be disconnected before testing switch continuity. SWITCH CIRCUIT IDENTIFICATION Stop Lamp Switch Terminal Identification - Terminals 1 and 2 are for the RWAL/ABS module and Powertrain Control Module (PCM) circuit. - Terminals 5 and 6 are for the stop lamp circuit. - Terminals 3 and 4 are for the speed control circuit. SWITCH CONTINUITY TEST 1. Check continuity between terminal pins 5 and 6 as follows: a. Pull plunger all the way out to fully extended position. b. Attach test leads to pins 5 and 6 and note ohmmeter reading. c. If continuity exists, proceed to next test. Replace switch if meter indicates lack of continuity (shorted or open). 2. Check continuity between terminal pins 1 and 2 and pins 3 and 4 as follows: a. Push switch plunger inward to fully retracted position. b. Attach test leads to pins 1 and 2 and note ohmmeter reading. c. If continuity exists, switch is OK. Replace switch if meter indicates lack of continuity (switch is open). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6919 Brake Light Switch: Adjustments The switch can be adjusted by lightly pulling the brake pedal rearward against the internal booster stop. This will set the switch plunger to the proper position. CAUTION: Do not use excessive force to pull the pedal rearward. Excessive force will damage switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6920 Brake Light Switch: Service and Repair REMOVAL 1. Remove lower column cover. 2. Remove the Data Link Connector, hood release lever and park brake release lever from the knee blocker. 3. Remove the knee blocker for access to switch. 4. Press and hold brake pedal in applied position. Stop Lamp Switch Mounting 5. Rotate stop lamp switch counterclockwise about 1/16 turn to unlock switch. Then pull switch straight out of mounting bracket and release brake pedal. 6. If switch is to be tested or replaced, disconnect wire harness and remove switch from vehicle. INSTALLATION 1. Pull switch plunger all the way out. Then push plunger 4 notches inward to preset position. Plunger length out of housing will be approximately 14 mm (0.55 inch). 2. Plug wire harness connector into switch. 3. Press and hold brake pedal in applied position. 4. Align switch locking collar index in switch bracket. Then insert switch straight into bracket. 5. Turn switch clockwise about 1/16 turn to lock it in position. 6. Release brake pedal. 7. Lightly pull brake pedal rearward against internal stop in booster. CAUTION: Do not use excessive force to move the pedal rearward for switch adjustment. Excessive force will damage the switch. 8. Install the knee blocker. 9. Install the Data Link Connector, hood release lever and park brake release lever to the knee blocker. 10. Install lower column cover. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams Door Switch: Diagrams Left Front Door Ajar Switch Connector Right Front Door Ajar Switch Connector Auxiliary Door Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 6924 Auxiliary Door Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Reach through and above the instrument panel glove box opening upper reinforcement to depress the retaining tabs on the top and bottom of the glove box lamp and switch housing. Glove Box Lamp And Switch Remove/Install 4. While holding the retaining tabs depressed, push the glove box lamp and switch unit out through the hole in the mounting tab on the upper instrument panel glove box opening. 5. Pull the glove box lamp and switch out through the mounting tab far enough to access and unplug the two wire harness connectors. 6. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation Hazard Warning Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch assembly, which is secured to the left side of the steering column. A switch stalk that extends from the left side of the multi-function switch is moved up or down to activate the right or left turn signals, respectively A latching push-button that extends upward from the multi-function switch and through the top of the upper steering column shroud is used to control the hazard warning system. The multi-function switch also contains circuitry for the following functions: Headlamp beam selection - Headlamp optical horn - Horn contact and circuit - Windshield wipers - Windshield washers. The information contained addresses only the multi-function switch turn signal and hazard warning switches. For information relative to the other circuits and switches that are integral to the multi-function switch. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit of the multi-function switch is faulty or damaged, the entire multi-function switch assembly must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 6931 Hazard Warning Switch: Testing and Inspection The turn signal switch and the hazard warning switch are integral to the multi-function switch. See Turn Signal and Hazard Warning Systems in the Diagnosis and Testing before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Unplug the steering column wire harness connector. Turn Signal Switch And Hazard Warning Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the steering column half of the steering column wire harness connector terminals as shown in the Turn Signal Switch and Hazard Warning Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, repair the open circuit in the steering column wire harness or replace the faulty multi-function switch assembly as required. If the switches are OK, repair the lighting circuits as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 6932 Hazard Warning Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. Refer to Airbag Module in the Removal and Installation for the procedures. 3. if the vehicle is equipped with the optional vehicle speed control, unplug the wire harness connectors from the speed control switches in the steering wheel. 4. Remove the nut that secures the steering wheel to the steering column upper shaft. 5. Remove the steering wheel with a steering wheel puller (Special Tool C-3428-B). 6. Remove the knee blocker from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Knee Diverter/Knee Blocker Replacement. 7. If the vehicle is so equipped, remove the tilt steering column lever by grasping the lever firmly and pulling it sharply away from the column. Lower Steering Column Shroud Screws 8. Remove the two screws from the bottom of the lower steering column shroud that secure it to the upper shroud. 9. Unsnap the front and both sides of the lower shroud from the upper shroud. Lower Steering Column Shroud Remove/Install 10. Tilt the lower shroud downward and slide it back to disengage the hooks from the pivots on the upper shroud. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 6933 Upper Steering Column Shroud Remove/Install 11. Remove the two screws that secure the upper shroud to the steering column. 12. Remove the upper shroud from the steering column. Steering Column Tie-Wraps 13. Remove the two lower wire harness tie wraps. 14. Remove the screw from the center of the steering column wire harness connector and unplug the two halves of the connector. 15. Disengage the two multi-function switch wire harness connectors (one 17-way and one 13-way) from the steering column wire harness insulator. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 6934 Multi-Function Switch Remove/Install 16. Remove the two screws that secure the multi-function switch to the steering column. 17. Remove the multi-function switch from the steering column. 18. Reverse the removal procedures to install. During installation, check that the following procedures are accomplished: - Tighten the multi-function switch mounting screws to 6 N.m (53 in. lbs.). - Be certain that the new wire harness tie-wraps are installed in the same positions as those that were removed. - Be certain that the steering column wire harnesses are routed so that they will not be pinched or stretched. - Be certain that the upper shroud spacer mounting stud is fully seated to the mounting boss on the inside of the shroud. - Tighten the upper shroud mounting screws to 1.4 N.m (12 in. lbs.). - Tighten the lower shroud mounting screws to 3.4 N.m (30 in. lbs.). - Be certain to index the alignment splines in the hub of the steering wheel with the splines on the upper steering column shaft. - Be certain to route the wire harnesses from the clockspring between the steering wheel back trim cover and the steering wheel armature. - Tighten the steering wheel nut to 61 N.m (45 ft. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Headlamp Switch Connector Headlamp Switch Ground Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 6938 Headlamp Switch: Testing and Inspection Headlamp Diagnosis When a vehicle experiences problems with the headlamp system, verify the condition of the battery connections, charging system, headlamp bulbs, wire connectors, relay, high beam dimmer switch and headlamp switch. Always begin any diagnosis by testing all of the fuses and circuit breakers in the system. Conventional and halogen headlamps are interchangeable. It is recommended that they not be intermixed on a given vehicle. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 6939 Headlamp Switch: Service and Repair WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - IF THE HEADLAMP SWITCH WAS ON, WAIT FIVE MINUTES TO ALLOW THE CERAMIC DIMMER RESISTOR TO COOL. IF THE CERAMIC DIMMER RESISTOR IS NOT ALLOWED TO COOL, IT CAN BURN YOUR FINGERS. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. See Cluster Bezel Replacement for the procedures. 3. Remove the three screws that secure the headlamp switch bezel to the instrument panel. Headlamp Switch And Bezel Remove/Install 4. Pull the headlamp switch and bezel out from the instrument panel far enough to access and unplug the wire harness connectors. 5. Pull the headlamp switch control knob out to the On position stop. 6. Depress the headlamp switch knob and shaft release button on the top of the switch. 7. While holding the release button depressed, pull the knob and shaft out of the headlamp switch. 8. Remove the spanner nut that secures the headlamp switch bezel and mounting bracket to the switch. 9. Remove the headlamp switch bezel and mounting bracket from the switch. 10. Reverse the removal procedures to install. Tighten the headlamp switch and bezel mounting screws to 2.2 N.m (20 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Horn Switch: Locations A center-blow, resistive membrane-type horn switch is installed on the back side of the driver side airbag module trim cover in the center of the steering wheel. When the center area of the airbag trim cover is depressed, the horn switch completes a curcuit to ground for the coil side of the horn relay. The steering wheel and steering column must be properly grounded for the horn switch to function. The horn switch is only serviced as a part of the airbag module trim cover. If the horn switch should fail, or if the airbag is deployed, the airbag module trim cover and horn switch must be replaced as a unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 6943 Horn Switch: Description and Operation SYSTEM OPERATION A center-blow, resistive membrane-type horn switch is installed on the back side of the driver side airbag module trim cover in the center of the steering wheel. When the center area of the airbag trim cover is depressed, the horn switch completes a circuit to ground for the coil side of the horn relay. The steering wheel and steering column must be properly grounded for the horn switch to function. The horn switch is only serviced as a part of the airbag module trim cover. If the horn switch should fail, or if the airbag is deployed, the airbag module trim cover and horn switch must be replaced as a unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 6944 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover and knee blocker from the instrument panel. 2. Check for continuity between the metal steering column jacket and a good ground. There should be continuity. If OK, go to Step 4. If not OK, refer to Steering and Suspension/Steering Column. 3. Remove the driver side airbag module from the steering wheel. Refer to Airbag Module in Air Bags and Seat Belts/Air Bags for the procedures. Unplug the horn switch wire harness connector from the air-bag module. 4. Unplug the horn relay from the junction block. Check for continuity between the steering column half of the horn switch feed wire harness connector and a good ground. There should be no continuity If OK, go to Step 6. If not OK, see Horn Contact in the Diagnosis and Testing. 5. Check for continuity between the steering column half of the horn switch feed wire harness connector and the horn relay control circuit cavity for the horn relay in the PDC. There should be continuity If OK, go to Step 7. If not OK, see Horn Tower in the Diagnosis and Testing. 6. Check for continuity between the horn switch feed wire and the horn switch ground wire on the airbag module. There should be no continuity. If OK, go to Step 8. If not OK, replace the faulty horn switch. 7. Depress the center of the airbag module trim cover and check for continuity between the horn switch feed wire and the horn switch ground wire on the airbag module. There should now be continuity If not OK, replace the faulty horn switch. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Driver Side Airbag Trim Cover and Horn Switch Horn Switch: Service and Repair Driver Side Airbag Trim Cover and Horn Switch REMOVAL WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE HORN SWITCH IS INTEGRAL TO THE AIRBAG MODULE TRIM COVER. SERVICE OF THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the driver side airbag module from the steering wheel. See Airbag Module - Driver Side in the Replacement. Airbag Trim Cover Retainer Nuts Remove/Install 3. Remove the four nuts that secure the upper and lower trim cover retainers to the studs on the airbag housing. Airbag Trim Cover Retainers Remove/Install 4. Remove the upper and lower trim cover retainers from the airbag housing studs. 5. Remove the horn switch ground wire eyelet from the airbag housing stud. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Driver Side Airbag Trim Cover and Horn Switch > Page 6947 Airbag Trim Cover Remove/Install 6. Disengage the six trim cover locking blocks from the lip around the outside edge of the airbag housing and remove the housing from the cover. WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE DRIVER SIDE AIRBAG MODULE TRIM COVER AND THE DRIVER SIDE AIRBAG MODULE. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. 7. When installing the trim cover and horn switch, be certain that the locking blocks are fully engaged on the lip of the airbag housing. Driver Side Airbag Trim Cover Locking Blocks Engaged 8. When installing the upper and lower trim cover retainers, be certain that the tabs on each retainer are engaged in the retainer slots of the trim cover. 9. Install and tighten the trim cover retainer nuts to 10 N.m (90 in. lbs.). 10. Reverse the remaining removal procedures to complete the installation, but do not connect the battery negative cable at this time. See Airbag System in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Driver Side Airbag Trim Cover and Horn Switch > Page 6948 Horn Switch: Service and Repair Horn Switch REMOVAL AND INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH A DRIVER SIDE AIRBAG, THE HORN SWITCH IS INTEGRAL TO THE AIRBAG MODULE TRIM COVER. SERVICE OF THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REFER TO DRIVER SIDE AIR-BAG TRIM COVER AND HORN SWITCH IN THE REMOVAL AND INSTALLATION SECTION OF AIRBAG FOR THE SERVICE PROCEDURES . Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams Courtesy Lamp Defeat Switch Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Description and Operation Turn Signal Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch assembly, which is secured to the left side of the steering column. A switch stalk that extends from the left side of the multi-function switch is moved up or down to activate the right or left turn signals, respectively A latching push-button that extends upward from the multi-function switch and through the top of the upper steering column shroud is used to control the hazard warning system. The multi-function switch also contains circuitry for the following functions: Headlamp beam selection - Headlamp optical horn - Horn contact and circuit - Windshield wipers - Windshield washers. The information contained addresses only the multi-function switch turn signal and hazard warning switches. For information relative to the other circuits and switches that are integral to the multi-function switch. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit of the multi-function switch is faulty or damaged, the entire multi-function switch assembly must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Description and Operation > Page 6955 Turn Signal Switch: Testing and Inspection Turn Signal Switch and Hazard Warning Switch The turn signal switch and the hazard warning switch are integral to the multi-function switch. See Turn Signal and Hazard Warning Systems in the Diagnosis and Testing before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Unplug the steering column wire harness connector. Turn Signal Switch And Hazard Warning Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the steering column half of the steering column wire harness connector terminals as shown in the Turn Signal Switch and Hazard Warning Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, repair the open circuit in the steering column wire harness or replace the faulty multi-function switch assembly as required. If the switches are OK, repair the lighting circuits as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Description and Operation > Page 6956 Turn Signal Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. Refer to Airbag Module in the Removal and Installation for the procedures. 3. if the vehicle is equipped with the optional vehicle speed control, unplug the wire harness connectors from the speed control switches in the steering wheel. 4. Remove the nut that secures the steering wheel to the steering column upper shaft. 5. Remove the steering wheel with a steering wheel puller (Special Tool C-3428-B). 6. Remove the knee blocker from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Knee Diverter/Knee Blocker Replacement. 7. If the vehicle is so equipped, remove the tilt steering column lever by grasping the lever firmly and pulling it sharply away from the column. Lower Steering Column Shroud Screws 8. Remove the two screws from the bottom of the lower steering column shroud that secure it to the upper shroud. 9. Unsnap the front and both sides of the lower shroud from the upper shroud. Lower Steering Column Shroud Remove/Install 10. Tilt the lower shroud downward and slide it back to disengage the hooks from the pivots on the upper shroud. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Description and Operation > Page 6957 Upper Steering Column Shroud Remove/Install 11. Remove the two screws that secure the upper shroud to the steering column. 12. Remove the upper shroud from the steering column. Steering Column Tie-Wraps 13. Remove the two lower wire harness tie wraps. 14. Remove the screw from the center of the steering column wire harness connector and unplug the two halves of the connector. 15. Disengage the two multi-function switch wire harness connectors (one 17-way and one 13-way) from the steering column wire harness insulator. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Description and Operation > Page 6958 Multi-Function Switch Remove/Install 16. Remove the two screws that secure the multi-function switch to the steering column. 17. Remove the multi-function switch from the steering column. 18. Reverse the removal procedures to install. During installation, check that the following procedures are accomplished: - Tighten the multi-function switch mounting screws to 6 N.m (53 in. lbs.). - Be certain that the new wire harness tie-wraps are installed in the same positions as those that were removed. - Be certain that the steering column wire harnesses are routed so that they will not be pinched or stretched. - Be certain that the upper shroud spacer mounting stud is fully seated to the mounting boss on the inside of the shroud. - Tighten the upper shroud mounting screws to 1.4 N.m (12 in. lbs.). - Tighten the lower shroud mounting screws to 3.4 N.m (30 in. lbs.). - Be certain to index the alignment splines in the hub of the steering wheel with the splines on the upper steering column shaft. - Be certain to route the wire harnesses from the clockspring between the steering wheel back trim cover and the steering wheel armature. - Tighten the steering wheel nut to 61 N.m (45 ft. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair Tail Light Bulb: Service and Repair REMOVAL 1. Remove the screws attaching the lamp to the vehicle. Bulb Socket Removal 2. Rotate the bulb socket 1/4 turn counterclockwise to remove it from the housing. 3. Pull the bulb straight out of the socket to remove it. INSTALLATION 1. Press bulb into socket and position socket in housing. 2. Rotate the bulb socket 1/4 turn clock-wise to install in the housing. 3. Position the lamp on the vehicle and install screws. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation Turn Signal Flasher: Description and Operation SYSTEM OPERATION The combination flasher is a smart relay that functions as both the turn signal system and hazard warning system flasher. The combination flasher contains active electronic Integrated Circuitry (IC) elements. This flasher is designed to handle the current flow requirements of the factory-installed lighting. If supplemental lighting is added to the turn signal lamp circuits, such as when towing a trailer with lights, the combination flasher will automatically try to compensate to keep the flash rate the same. While the combination flasher has a International Standards Organization (ISO)-type relay terminal configuration or footprint, the internal circuitry is much different. The combination flasher does not use standard 150-relay inputs or provide ISO-relay type outputs or functions. The combination flasher should never be substituted for an ISO-relay or replaced with an ISO-relay, or else component and vehicle damage may occur. Combination Flasher - Typical The combination flasher has five blade-type terminals intended for the following inputs and outputs: Battery B+, Ignition B+, Ground, Turn Signal circuit, and Hazard Warning circuit. Constant battery voltage and ground are supplied to the flasher so that it can perform the hazard warning function, and ignition switched battery voltage is supplied for the turn signal function. The IC within the combination flasher contains the logic that controls the flasher operation and the flash rate. Pin 6 of the IC receives a sense voltage from the hazard warning portion of the multi-function switch. When the hazard switch is turned on, the "hazard on sense" voltage will become low due to the circuit being grounded through the turn signal bulbs. This low voltage sense signals the IC to energize the flash control Positive-Negative-Positive (PNP) transistor at a pre-calibrated flash rate or frequency Each time the PNP transistor energizes the hazard warning circuit, the pin 6 "hazard on sense" voltage will become high and the IC signals the PNP transistor to de-energize the circuit. This cycling will continue until the hazard warning switch is turned off. Likewise, pin 8 of the IC receives a sense voltage from the turn signal portion of the multi-function switch. When the left or right turn signal is turned on, the "turn signal on sense" voltage will become low due to the circuit being grounded through the turn signal bulbs. This low voltage sense signals the IC to energize the flash control PNP transistor at a precalibrated flash rate or frequency. Each time the PNP transistor energizes the turn signal circuit, the pin 8 "turn signal on sense" voltage will become high and the IC signals the PNP transistor to de-energize the circuit. This cycling will continue until the right or left turn signal is turned off. A special design feature of the combination flasher allows it to "sense" that a turn signal circuit or bulb is not operating, and provide the driver an indication of the condition by flashing the remaining bulbs in the affected circuit at a higher rate (120 flashes-per-minute or higher). Conventional flashers either continue flashing at their typical rate (heavy-duty type), or discontinue flashing the affected circuit entirely (standard-duty type). During turn signal operation, the combination flasher IC compares normal battery voltage input on pin 2 with the shunt resistor voltage input on pin 7. If the IC "senses" that the voltage difference between pin 2 and pin 7 is different than the pre-calibrated value of the IC, it will increase the rate at which it signals the PNP transistor to energize the pin 1 output. Thus, the inoperative half (left or right side) of the turn signal circuit will flash faster. Because of the active electronic elements within the combination flasher, it cannot be tested with conventional automotive electrical test equipment. If the combination flasher is believed to be faulty; test the turn signal and hazard warning system circuits as described. Then replace the combination flasher with a known good unit to confirm system operation. The combination flasher cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 6967 Turn Signal Flasher: Service and Repair REMOVAL AND INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the end cap from the driver side end of the instrument panel. Refer to Instrument Panel Gauges and Warning Systems/Instrument Panel/Instrument Panel End Cap Replacement. Junction Block 3. Unplug the combination flasher from the junction block. 4. Install the combination flasher by aligning the flasher terminals with the cavities in the junction block and pushing the flasher firmly into place. 5. Connect the battery negative cable. 6. Test the flasher operation. 7. Reinstall the end cap on the instrument panel. Refer to Instrument Panel Gauges and Warning Systems/Instrument Panel/Instrument Panel End Cap Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation Turn Signal Indicator: Description and Operation SYSTEM OPERATION The left and right turn signal indicator lamps give an indication when the turn signal circuits are activated. The lamps are hard wired in the instrument cluster, and are completely controlled by the turn signal and hazard warning (multi-function) switches. The indicator lamps are grounded at all times and receive battery feed through the contacts of the multi-function switch when the turn signal lever (multi-function switch stalk) or the hazard warning button are actuated to their On positions. The instrument cluster circuitry does not perform a bulb test of these lamps. Refer to Lighting and Horns/Turn Signal and Hazard Warning Systems for more information. The turn signal indicator lamps are located in the instrument duster. They flash with the exterior turn signal lamps to give the driver a visual indication that a turn signal or the hazard warning system is operating. Refer to Turn Signal Indicator Lamp in Instrument Panel Systems and Lighting and Horns for diagnosis or service of these lamps. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation > Page 6971 Turn Signal Indicator: Testing and Inspection The diagnosis found here addresses an inoperative turn signal indicator lamp condition. For any other turn signal problem, refer to Lighting and Horns /Turn Signal and Hazard Warning Systems for diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the instrument cluster. 2. Connect the battery negative cable. Activate the hazard warning system by moving the hazard warning switch button to the On position. Check for battery voltage at the inoperative (right or left) turn signal circuit cavity of the instrument cluster wire harness connector (connector B). There should be a switching (on and off) battery voltage signal. If OK, replace the faulty (right or left) turn signal indicator lamp bulb. if not OK, repair the open circuit to the turn signal/hazard warning (multi-function) switch as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Tail, Stop, Turn Signal, Back-Up and Side Marker Lamp Bulbs Turn Signal Bulb: Service and Repair Tail, Stop, Turn Signal, Back-Up and Side Marker Lamp Bulbs REMOVAL 1. Remove the screws attaching the lamp to the vehicle. Bulb Socket Removal 2. Rotate the bulb socket 1/4 turn counterclockwise to remove it from the housing. 3. Pull the bulb straight out of the socket to remove it. INSTALLATION 1. Press bulb into socket and position socket in housing. 2. Rotate the bulb socket 1/4 turn clock-wise to install in the housing. 3. Position the lamp on the vehicle and install screws. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Tail, Stop, Turn Signal, Back-Up and Side Marker Lamp Bulbs > Page 6977 Turn Signal Bulb: Service and Repair Turn Signal and Side Marker Lamp Bulb REMOVAL 1. Raise hood and position support rod. 2. Remove the screws from the sidemarker and turn signal lamp housing and pull out to disengage the outboard pin clip to remove the housing. Sidemarker And Turn Signal Bulb Removal 3. To remove the bulb, twist the it 1/4 turn counterclock-wise and remove it from the housing 4. Pull the bulb straight out of the socket. INSTALLATION 1. Push the replacement bulb into the socket. 2. Position the bulb in the housing and twist it 1/4 turn clock-wise. 3. Align the outboard pin clip and position the housing on the vehicle. Install the screws. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Description and Operation Turn Signal Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch assembly, which is secured to the left side of the steering column. A switch stalk that extends from the left side of the multi-function switch is moved up or down to activate the right or left turn signals, respectively A latching push-button that extends upward from the multi-function switch and through the top of the upper steering column shroud is used to control the hazard warning system. The multi-function switch also contains circuitry for the following functions: Headlamp beam selection - Headlamp optical horn - Horn contact and circuit - Windshield wipers - Windshield washers. The information contained addresses only the multi-function switch turn signal and hazard warning switches. For information relative to the other circuits and switches that are integral to the multi-function switch. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit of the multi-function switch is faulty or damaged, the entire multi-function switch assembly must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Description and Operation > Page 6981 Turn Signal Switch: Testing and Inspection Turn Signal Switch and Hazard Warning Switch The turn signal switch and the hazard warning switch are integral to the multi-function switch. See Turn Signal and Hazard Warning Systems in the Diagnosis and Testing before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Unplug the steering column wire harness connector. Turn Signal Switch And Hazard Warning Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the steering column half of the steering column wire harness connector terminals as shown in the Turn Signal Switch and Hazard Warning Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, repair the open circuit in the steering column wire harness or replace the faulty multi-function switch assembly as required. If the switches are OK, repair the lighting circuits as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Description and Operation > Page 6982 Turn Signal Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. Refer to Airbag Module in the Removal and Installation for the procedures. 3. if the vehicle is equipped with the optional vehicle speed control, unplug the wire harness connectors from the speed control switches in the steering wheel. 4. Remove the nut that secures the steering wheel to the steering column upper shaft. 5. Remove the steering wheel with a steering wheel puller (Special Tool C-3428-B). 6. Remove the knee blocker from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Knee Diverter/Knee Blocker Replacement. 7. If the vehicle is so equipped, remove the tilt steering column lever by grasping the lever firmly and pulling it sharply away from the column. Lower Steering Column Shroud Screws 8. Remove the two screws from the bottom of the lower steering column shroud that secure it to the upper shroud. 9. Unsnap the front and both sides of the lower shroud from the upper shroud. Lower Steering Column Shroud Remove/Install 10. Tilt the lower shroud downward and slide it back to disengage the hooks from the pivots on the upper shroud. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Description and Operation > Page 6983 Upper Steering Column Shroud Remove/Install 11. Remove the two screws that secure the upper shroud to the steering column. 12. Remove the upper shroud from the steering column. Steering Column Tie-Wraps 13. Remove the two lower wire harness tie wraps. 14. Remove the screw from the center of the steering column wire harness connector and unplug the two halves of the connector. 15. Disengage the two multi-function switch wire harness connectors (one 17-way and one 13-way) from the steering column wire harness insulator. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Description and Operation > Page 6984 Multi-Function Switch Remove/Install 16. Remove the two screws that secure the multi-function switch to the steering column. 17. Remove the multi-function switch from the steering column. 18. Reverse the removal procedures to install. During installation, check that the following procedures are accomplished: - Tighten the multi-function switch mounting screws to 6 N.m (53 in. lbs.). - Be certain that the new wire harness tie-wraps are installed in the same positions as those that were removed. - Be certain that the steering column wire harnesses are routed so that they will not be pinched or stretched. - Be certain that the upper shroud spacer mounting stud is fully seated to the mounting boss on the inside of the shroud. - Tighten the upper shroud mounting screws to 1.4 N.m (12 in. lbs.). - Tighten the lower shroud mounting screws to 3.4 N.m (30 in. lbs.). - Be certain to index the alignment splines in the hub of the steering wheel with the splines on the upper steering column shaft. - Be certain to route the wire harnesses from the clockspring between the steering wheel back trim cover and the steering wheel armature. - Tighten the steering wheel nut to 61 N.m (45 ft. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Light Bulb > Component Information > Service and Repair Underhood Light Bulb: Service and Repair REMOVAL 1. Insert a small flat blade in the access slot between the lamp base and lamp lens. Underhood Lamp Lens 2. Pry the lamp lens upward and remove the lamp lens. Underhood Lamp Bulb 3. Depress the bulb terminal inward to release the bulb. INSTALLATION 1. Engage the replacement bulb wire loop to the terminal closest to the lamp base wire connector. 2. Depress the opposite terminal inward and engage the remaining bulb wire loop. 3. Position the lamp lens on the lamp base and press into place. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Service and Repair > Lamp Replacement Vanity Lamp: Service and Repair Lamp Replacement REMOVAL 1. Fold down sunvisor. 2. Starting at the base of the lamp assembly and working right-to-left, use a small flat blade, carefully pry lamp from visor. 3. Disconnect visor lamp wire connector and remove from vehicle. INSTALLATION 1. Position visor lamp at visor and connect visor lamp wire connector. 2. Position visor lamp in visor and press into place. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Service and Repair > Lamp Replacement > Page 6993 Vanity Lamp: Service and Repair Bulb Replacement REMOVAL 1. Using a small flat blade, carefully pry each corner of lens outward from lamp. 2. Separate lens from lamp. 3. Grasp bulb and pull outward. INSTALLATION 1. Position bulb in socket and push into place. 2. Position lens on lamp and snap into place. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions Heated Glass Element: Diagram Information and Instructions Introduction 8w-01-002 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6999 8w-01-003 Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7000 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7001 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7002 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7003 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7004 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7005 8w-01-006 International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7006 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7007 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7008 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7009 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7010 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7011 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7012 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7013 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7014 Heated Glass Element: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7015 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7016 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Page 7017 Heated Glass Element: Description and Operation INTRODUCTION An electrically heated rear window defogger is optional factory-installed equipment on this model, when it is equipped with a single rear cargo door. Rear Window Defogger System The rear window defogger system will only operate when the ignition switch is in the On position. When the defogger switch is in the On position, an electric heater grid on the rear window glass is energized. The electric heater grid produces heat to help clear the rear window glass of ice, snow, or fog. The defogger system is controlled by a momentary switch that is integral to the heater and air conditioner control assembly, which is located below the radio in the instrument cluster bezel on the instrument panel. An amber indicator lamp above the switch will light to indicate when the defogger system is turned on. The heater and air conditioner control assembly also contains the defogger system timer and logic circuitry, and an integral defogger relay. The defogger system will be automatically turned off after a programmed time interval of about ten minutes. After the initial time interval has expired, if the defogger switch is turned on again during the same ignition cycle, the defogger system will automatically turn off after about five minutes. The defogger system will automatically shut off if the ignition switch is turned to the Off position, or it can be turned off manually by depressing the defogger switch again. Following are general descriptions of the major components in the rear window defogger system. Refer to the owner's manual in the vehicle glove box for more information on the features, use and operation of the rear window defogger system. SYSTEM OPERATION Rear Glass Heating Grid The heated rear window glass has two electrically conductive vertical bus bars and a series of horizontal grid lines made of a silver-ceramic material, which is baked on and bonded to the inside surface of the glass. The grid lines and bus bars comprise a parallel electrical circuit. When the rear window defogger switch is placed in the On position, electrical current is directed to the rear window grid lines through the bus bars. The grid lines heat the rear window to clear the surface of fog or snow. Protection for the heating grid circuit is provided by a fuse in the Power Distribution Center (PDC). The grid lines and bus bars are highly resistant to abrasion. However, it is possible for an open circuit to occur in an individual grid line, resulting in no current flow through the line. The grid lines can be damaged or scraped off with sharp instruments. Care should be taken when cleaning the glass or removing foreign materials, decals, or stickers from the glass. Normal glass deaning solvents or hot water used with rags or toweling is recommended. A repair kit is available to repair the grid lines and bus bars, or to reinstall the heated glass terminals. Rear Window Defogger System Control The rear window defogger switch, rear window defogger indicator lamp, rear window defogger mirror electronic timer/control/logic circuitry and rear window defogger relay are all integral to the heater and air conditioner control assembly, which is located below the radio in the instrument cluster bezel on the instrument panel. The momentary-type switch provides a hard wired battery signal to the electronic circuitry each time it is depressed. An amber rear window defogger indicator lamp above the rear window defogger switch lights to indicate when the rear window defogger system is turned On. The rear window defogger electronic timer/control/ logic circuitry responds to the swift input by energizing or de-energizing the rear window defogger relay. Energizing the rear window defogger relay provides electrical current to the rear glass heating grid. The rear window defogger switch, rear window defogger indicator lamp, rear window defogger electronic timer/control/logic circuitry and rear window defogger relay cannot be repaired. if damaged or faulty, the entire heater and air conditioner control assembly must be replaced. Refer to Heater-A/C Control in the Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Detecting Breaks in Rear Window Defogger Grid Heated Glass Element: Testing and Inspection Detecting Breaks in Rear Window Defogger Grid To detect breaks in the grid lines, the following procedure is required: 1. Turn the ignition switch to the On position. Set the defogger switch in the On position. The indicator lamp should light. If OK, go to Step 3. If not OK, see Rear window Defogger System Control in the Diagnosis and Testing. 2. Using a 12-volt DC voltmeter, contact the vertical bus bar on the right side of the vehicle with the negative lead. With the positive lead, contact the vertical bus bar on the left side of the vehicle. The voltmeter should read battery voltage. If OK, go to Step 4. If not OK, repair the open circuit to the rear window defogger system control as required. 3. With the negative lead of the voltmeter, contact a good body ground point. The voltage reading should not change. If OK, go to Step 5. If not OK, repair the circuit to ground as required. 4. Connect the negative lead of the voltmeter to the right side bus bar and touch each grid line at midpoint C with the positive lead. A reading of approximately six volts indicates a line is good. A reading of zero volts indicates a break in the grid line between midpoint C and the left side bus bar. A reading of ten to fourteen volts indicates a break between midpoint C and the right side bus bar. Move the positive lead on the grid line towards the break and the voltage reading will change as soon as the break is crossed. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Detecting Breaks in Rear Window Defogger Grid > Page 7020 Heated Glass Element: Testing and Inspection Defogger System Operation Check WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The operation of the electrically heated rear window defogger system can be confirmed in one of the following manners: 1. Turn the ignition switch to the On position. While monitoring the instrument panel voltmeter, set the defogger switch in the On position. When the defogger switch is turned On, a distinct voltmeter needle deflection should be noted. 2. Turn the ignition switch to the On position. Set the defogger switch in the On position. The rear window defogger operation can be checked by feeling the rear window glass. A distinct difference in temperature between the grid lines and the adjacent clear glass can be detected within three to four minutes of operation. Rear Window Glass Grid Test 3. Using a 12-volt DC voltmeter, contact the rear glass heating grid terminal A (right side) with the negative lead, and terminal B (left side) with the positive lead. The voltmeter should read battery voltage. The above checks will confirm system operation. Illumination of the defogger switch indicator lamp means that there is electrical current available at the output of the rear window defogger logic and timer circuitry, but does not confirm that the electrical current is reaching the rear glass heating grid lines. If the defogger system does not operate, the problem should be isolated in the following manner: 1. Confirm that the ignition switch is in the On position. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Detecting Breaks in Rear Window Defogger Grid > Page 7021 Rear Window Defogger System 2. Ensure that the rear glass heating grid feed and ground wires are connected to the glass. Confirm that the ground wire has continuity to ground, and that there is continuity between the electrical contacts in the rear door hinge pillar when the rear door is closed. 3. Check the fuses in the Power Distribution Center (PDC) and in the junction block. The fuses must be tight in their receptacles and all electrical connections must be secure. When the above steps have been completed and the rear glass heating grid is still inoperative, one or more of the following is faulty: - Defogger system control - Rear window grid lines (all grid lines would have to be broken or one of the feed wires disconnected for the entire system to be inoperative). If setting the defogger switch to the On position produces a severe voltmeter deflection, check for a short circuit between the rear window defogger system control output and the rear glass heating grid. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Detecting Breaks in Rear Window Defogger Grid > Page 7022 Heated Glass Element: Testing and Inspection Defogger System Testing WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuses in the junction block and the Power Distribution Center (PDC). If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the PDC. If OK, go to Step 4. If not OK, repair the open circuit to the battery as required. 3. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 5. If not OK, repair the open circuit to the ignition switch as required. 4. Disconnect and isolate the battery negative cable. Remove the heater and air conditioner control from the instrument panel. Refer to Heater-A/C Control Replacement. Unplug the 4-way rear window defogger switch wire harness connector from the control. Check for continuity between the ground circuit cavity of the rear window defogger switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open circuit to ground as required. 5. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the rear window defogger switch wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the fuse in the PDC as required. 6. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity of the rear window defogger switch wire harness connector. If OK, go to Step 8. If not OK, repair the open circuit to the fuse in the junction block as required. 7. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Reconnect the 4-way rear window defogger switch wire harness connector to the heater and air conditioner control. Connect the battery negative cable. Turn the ignition switch to the On position. Depress and release the rear window defogger switch. The amber rear window defogger indicator lamp above the switch button should light. If OK, go to Step 9. If not OK, replace the faulty heater and air conditioner control assembly 8. Back probe the rear defogger relay output circuit cavity of the rear window defogger switch wire harness connector and check for battery voltage. If OK, see Rear Glass Heating Grid in the Diagnosis and Testing. If not OK, replace the faulty heater and air conditioner control assembly. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Service and Repair > Rear Glass Heating Grid Repair Heated Glass Element: Service and Repair Rear Glass Heating Grid Repair Repair of the rear glass heating grid lines, bus bars, terminals or pigtail wires can be accomplished using a Mopar Rear Window Defogger Repair Kit (Part Number 4267922) or equivalent. WARNING: MATERIALS CONTAINED IN THE REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION. THE KIT CONTAINS EPOXY RESIN AND AMINE TYPE HARDENER, WHICH ARE HARMFUL IF SWALLOWED. AVOID CONTACT WITH THE SKIN AND EYES. FOR SKIN CONTACT, WASH THE AFFECTED AREAS WITH SOAP AND WATER. FOR CONTACT WITH THE EYES, FLUSH WITH PLENTY OF WATER. DO NOT TAKE INTERNALLY. IF TAKEN INTERNALLY, INDUCE VOMITING AND CALL A PHYSICIAN IMMEDIATELY. USE WITH ADEQUATE VENTILATION. DO NOT USE NEAR FIRE OR FLAME. CONTAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE REACH OF CHILDREN. 1. Mask the repair area so that the conductive epoxy can be applied neatly. Extend the epoxy application onto the grid line or the bus bar on each side of the break. 2. Follow the instructions in the repair kit for preparing the damaged area. 3. Remove the package separator clamp and mix the two conductive epoxy components thoroughly within the packaging. Fold the package in half and cut the center corner to dispense the epoxy 4. For grid line repairs, mask the area to be repaired with masking tape or a template. 5. Apply the epoxy through the slit in the masking tape or template. Overlap both ends of the break by at least 19 millimeters (0.75 inch). 6. For a terminal or pigtail wire replacement, mask the adjacent areas so the epoxy can be extended onto the adjacent grid line as well as the bus bar. Apply a thin layer of epoxy to the area where the terminal or pigtail wire was fastened and onto the adjacent grid line. 7. Apply a thin layer of conductive epoxy to the terminal or bare wire end of the pigtail and place it in the proper location on the bus bar. To prevent the terminal or pigtail wire from moving while the epoxy is curing, it must be wedged or damped. 8. Carefully remove the masking tape or template. CAUTION: Do not allow the glass surface to exceed 204° C (400° F) or the glass may fracture. 9. Allow the epoxy to cure 24 hours at room temperature, or use a heat gun with a 260° to 371° C (500° to 700° F) range for fifteen minutes. Hold the heat gun approximately 25.4 centimeters (10 inches) from the repair. 10. After the conductive epoxy is properly cured, remove the wedge or clamp from the terminal or pigtail wire. Do not attach the wire harness connectors until the curing process is complete. 11. Check the operation of the rear window defogger glass heating grid. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Service and Repair > Rear Glass Heating Grid Repair > Page 7025 Heated Glass Element: Service and Repair Rear Window Defogger Service procedures for the components used in the rear window defogger system can be found in the Removal and Installation Procedures, as follows: - Rear window defogger system control - refer to Heating and Air Conditioning Systems/Heater-A/C Control Replacement. - Rear glass heating grid - refer to Stationary Door Glass Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation Power Window Switch: Description and Operation SYSTEM OPERATION The power windows are controlled by two-way momentary switches mounted in the mirror flag bezel on the trim panel of each front door. A second power window switch on the driver side bezel allows the driver to control the passenger side window. The power windows will only operate when the ignition switch is in the On position. The power window switches control the battery and ground feeds to the power window motors. The passenger side power window switch receives a ground feed through the driver side power window switch for operating the passenger side power window motor. The power window switches cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Page 7030 Power Window Switch: Testing and Inspection Before you proceed with this diagnosis, confirm proper circuit breaker operation. See Circuit Breaker in the Diagnosis and Testing. 1. Remove the power window switch from the mirror flag bezel. See Power Window Switch Replacement. Carefully separate the wire harness connector from the switch body. Left Side Switch Continuity Power Window Switch Continuity - Passenger Side 2. Check the switch continuity in each position, as shown in the charts. If OK, see Power Window Motor in the Diagnosis and Testing. If not OK, replace the faulty power window switch unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Page 7031 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the mirror flag bezel from the inside of the front door. Power Window Switch Remove/Install 3. From the back side of the mirror flag bezel, remove the screws that secure the power window and power lock switch and mounting plate unit to the mirror flag bezel. 4. Remove the power window and power lock switch and mounting plate unit from the mirror flag bezel. 5. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power window switch receptacle on the back of the switch mounting plate and pull the switch out of the receptacle. 6. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the switch mounting plate are fully engaged. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Description and Operation Power Window Circuit Breaker: Description and Operation SYSTEM OPERATION An automatic resetting circuit breaker in the junction block is used to protect the power window system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck window glass or regulator. The circuit breaker cannot be repaired and, if faulty, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Description and Operation > Page 7036 Power Window Circuit Breaker: Testing and Inspection 1. Locate the circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. If the circuit breaker checks OK, but no power windows operate, see Power Window System in the Diagnosis and Testing. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Description and Operation > Page 7037 Power Window Circuit Breaker: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the end cap from the driver side end of the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/ Instrument Panel End Cap Replacement. Junction Block 3. Unplug the circuit breaker from the junction block. 4. Install the circuit breaker by aligning its terminals with the cavities in the junction block and pushing the circuit breaker firmly into place. 5. Connect the battery negative cable. 6. Test the circuit breaker operation. 7. Reinstall the end cap on the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/ Instrument Panel End Cap Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the front door. Power Window Motor Remove/Install 3. Disengage the power window motor wire harness connector retainer from the mounting hole on the front door module and unplug the connector. 4. Remove the three screws that secure the power window motor and mechanism to the front door module. 5. Remove the power window motor and mechanism from the front door module. 6. Reverse the removal procedures to install. Tighten the mounting screws to 11 N.m (98 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation Power Window Switch: Description and Operation SYSTEM OPERATION The power windows are controlled by two-way momentary switches mounted in the mirror flag bezel on the trim panel of each front door. A second power window switch on the driver side bezel allows the driver to control the passenger side window. The power windows will only operate when the ignition switch is in the On position. The power window switches control the battery and ground feeds to the power window motors. The passenger side power window switch receives a ground feed through the driver side power window switch for operating the passenger side power window motor. The power window switches cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > Page 7045 Power Window Switch: Testing and Inspection Before you proceed with this diagnosis, confirm proper circuit breaker operation. See Circuit Breaker in the Diagnosis and Testing. 1. Remove the power window switch from the mirror flag bezel. See Power Window Switch Replacement. Carefully separate the wire harness connector from the switch body. Left Side Switch Continuity Power Window Switch Continuity - Passenger Side 2. Check the switch continuity in each position, as shown in the charts. If OK, see Power Window Motor in the Diagnosis and Testing. If not OK, replace the faulty power window switch unit. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > Page 7046 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the mirror flag bezel from the inside of the front door. Power Window Switch Remove/Install 3. From the back side of the mirror flag bezel, remove the screws that secure the power window and power lock switch and mounting plate unit to the mirror flag bezel. 4. Remove the power window and power lock switch and mounting plate unit from the mirror flag bezel. 5. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power window switch receptacle on the back of the switch mounting plate and pull the switch out of the receptacle. 6. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the switch mounting plate are fully engaged. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation Wiper Control Module: Description and Operation SYSTEM OPERATION Intermittent Wipe Module An intermittent wipe module is used on vehicles that are not equipped with the optional Vehicle Theft Security System (VTSS). In addition to low and high speed, the intermittent wipe system has a delay mode. Electronic circuitry within the intermittent wipe module is used to accomplish the wiper delay mode. The delay time selected by the driver has a range of from about one-half second to about fourteen seconds. The driver selects the length of the delay by placing the wiper (multi-function) switch knob in one of five different intermittent wipe detent positions. One of the detent positions sends a battery voltage signal to the intermittent wipe module, while the other four positions use resistors to provide progressively lower voltage signals to the module. If the washer knob is depressed while the wiper switch is in the Off position, the intermittent wipe module will operate the wiper motor for approximately two wipes and automatically turn off the motor. The intermittent wipe module is snap-fit onto a single blade-type mounting bracket located on the instrument panel reinforcement above the glove box opening. The intermittent wipe module cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 7052 Wiper Control Module: Testing and Inspection Intermittent Wiper Module Testing The intermittent wipe module is used on vehicles that are not equipped with the Vehicle Theft Security System (VTSS). See Wiper System in the Diagnosis and Testing before performing the following tests. If the problem being diagnosed involves only some of the intermittent wipe delay positions, see Wiper Switch and Washer Switch in the Diagnosis and Testing. If the problem being diagnosed involves all of the intermittent wipe delay positions, proceed with the following tests. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Access and unplug the intermittent wipe module wire harness connector. Check for continuity between the ground circuit cavity of the intermittent wipe module wire harness connector and a good ground. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 2. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit of the intermittent wipe module wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit to the fuse in the junction block as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the wiper motor Check for continuity between the wiper park switch sense circuit (VS) cavities of the intermittent wipe module wire harness connector and the wiper motor wire harness connector. There should be continuity. If OK, go to Step 5. If not OK, repair the open circuit as required. 4. Unplug the steering column wire harness connector. Check for continuity between the wiper park switch sense circuit (V7) cavities of the intermittent wipe module wire harness connector and the instrument panel half of the steering column wire harness connector. There should be continuity. If OK, go to Step 6. If not OK, repair the open circuit as required. 5. Check for continuity between the wiper switch mode signal circuit cavities of the intermittent wipe module wire harness connector and the instrument panel half of the steering column wire harness connector. There should be continuity. If OK, go to Step 7. If not OK, repair the open circuit as required. 6. Check for continuity between the wiper switch delay output circuit cavities of the intermittent wipe module wire harness connector and the instrument panel half of the steering column wire harness connector. There should be continuity. If OK, go to Step 8. If not OK, repair the open circuit as required. 7. Test the multi-function switch continuity. See Wiper Switch and Washer Switch in the Diagnosis and Testing. If the switch tests OK, replace the faulty intermittent wipe module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 7053 Wiper Control Module: Service and Repair Intermittent Wipe Module Replacement REMOVAL An intermittent wipe module is used on vehicles that are not equipped with the optional Vehicle Theft Security System (VTSS). See Intermittent Wipe Module and Central Timer Module in the Description and Operation for more information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Roll down the glove box from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Glove Box - Roll Down Replacement. Instermittent Wiper Module Remove/Install 3. Reach through and above the glove box opening to access the intermittent wipe module. Push the module towards the front of the vehicle to disengage the snap-fit slot on the intermittent wipe module from the slide tab of the mounting bracket on the instrument panel armature. 4. Lower the intermittent wipe module into the instrument panel glove box opening far enough to access and unplug the wire harness connector. 5. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams Wiper Relay: Diagrams Intermittent Wiper Relay Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 7057 Wiper Relay: Description and Operation SYSTEM OPERATION An intermittent wipe relay is used on models that are equipped with the optional Vehicle Theft Security System (VTSS). The intermittent wipe relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The intermittent wipe relay is a electromechanical device that switches battery current to the windshield wiper motor when the relay coil is grounded by the Central Timer Module (CTM) in response to inputs from the windshield wiper (multi-function) switch. See Intermittent Wipe Relay in the Diagnosis. The intermittent wipe relay is located in a connector that is taped back to the instrument panel wire harness above the inboard side of the glove box opening. The intermittent wipe relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 7058 Wiper Relay: Testing and Inspection The intermittent wipe relay is used on vehicles that are equipped with the Vehicle Theft Security System (VTSS). See Wiper System in the Diagnosis and Testing before performing the following tests. If the problem being diagnosed involves only some of the intermittent wipe delay positions, see Wiper Switch and Washer Switch in the Diagnosis and Testing. If the problem being diagnosed involves all of the intermittent wipe delay positions, proceed with the following tests. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Test Instrument Wipe Relay The intermittent wipe relay is located in a connector that is taped back to the instrument panel wire harness above the inboard side of the glove box opening in the passenger compartment. Remove the intermittent wipe relay from its wire harness connector as described Replacement to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the wiper (multi-function) switch. There should be continuity between the cavity for relay terminal 30 and the two washer switch output (V11A and V11B) circuit cavities in the instrument panel half of the steering column wire harness connector at all times. If OK, go to Step 3. If not OK, repair the open circuit(s) to the wiper (mufti-function) switch as a required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position. There should be continuity between the cavity for relay terminal 87A and the wiper park switch sense circuit cavities of the wiper motor wire harness connector and the 14-way Central Timer Module (CTM) wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit(s) to the wiper motor and CTM as required. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. There should be battery voltage at the cavity for relay terminal 87 with the ignition switch in the On or Accessory positions. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the junction block as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On or Accessory positions. If OK, go to Step 6. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded by the CTM to energize the relay and cycle the wiper motor. a Check for continuity between the cavity for relay terminal 85 and the intermittent wiper relay control circuit cavity of the 14-way CTM wire harness connector. There should be continuity If OK, use a DRB scan tool and the proper Diagnostic Procedures for diagnosis of the CTM. If not OK, repair the open circuit to the CTM as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 7059 Wiper Relay: Service and Repair Intermittent Wipe Relay Replacement An intermittent wipe relay is used on vehicles that are equipped with the optional Vehicle Theft Security System (VTSS). See Intermittent Wipe Relay and Central Timer Module in the Description and Operation for more information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Roll down the glove box from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Glove Box - Roll Down Replacement. Intermittent Wipe Relay Remove/Install 3. Reach through and above the inboard side of the glove box opening to access the intermittent wipe relay. Remove the tape that secures the relay and its connector to the wire harness near the instrument panel armature. 4. Lower the intermittent wipe relay into the instrument panel glove box opening far enough to access and unplug the relay from its wire harness connector. 5. Install the intermittent wipe relay by aligning the relay terminals with the cavities in the wire harness connector and pushing the relay firmly into place. 6. Tape the intermittent wipe relay and its wire harness connector back to the wire harness. 7. Reinstall the glove box in the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Glove Box - Roll Down Replacement. 8. Connect the battery negative cable. 9. Test the relay operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation Washer Fluid Level Switch: Description and Operation SYSTEM OPERATION Washer Fluid Level Sensor The washer fluid level sensor is mounted near the bottom of the rearward facing side of the washer reservoir. A barbed nipple on the sensor is press-fit into a rubber grommet seal installed in the mounting hole on the reservoir. When the fluid level in the washer reservoir falls below the travel limit of the float, the internal switch contacts of the sensor close. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Low Washer Fluid Warning Lamp. The washer fluid level sensor cannot be repaired. If faulty or damaged, the sensor unit must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Page 7064 Washer Fluid Level Switch: Service and Repair REMOVAL 1. Remove the washer reservoir from the engine compartment. See Washer Reservoir Replacement. NOTE: The pivoting float of the washer fluid sensor must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and held in an upright position, the pivoting float will orient itself to the horizontal position when the sensor connector is pointed straight downwards. 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry the washer fluid level sensor out of the rubber grommet seal. Care must be taken not to damage the reservoir. 3. Remove the rubber grommet seal from the reservoir and discard. 4. Reverse the removal procedures to install. Always use a new rubber grommet seal on the reservoir. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation Windshield Washer Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch The windshield wiper and washer switches are integral to the multi-function switch assembly, which is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay interval. A paddle near the end of the switch stalk is rotated toward the instrument panel to activate the washer system. The multi-function switch also contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Horn contact and circuit. The information contained addresses only the multi-function switch windshield wiper and washer switches. For information relative to the other circuits and switches that are integral to the multi-function switch. However, the windshield wiper and washer switches cannot be repaired. If these switches or any other circuit of the multi-function switch is faulty or damaged, the entire multi-function switch assembly must be replaced. Refer to Turn Signal Switch and Hazard Warning Switch Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 7068 Windshield Washer Switch: Testing and Inspection The wiper switch and washer switch are integral to the multi-function switch. See Wiper System and/or Washer System in the Diagnosis and Testing WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Unplug the steering column wire harness connector. Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the steering column half of the steering column wire harness connector terminals as shown in the Wiper Switch and Washer Switch Continuity chart. 3. If the wiper switch or the washer switch fails any of the continuity checks, repair the open circuit in the steering column wire harness or replace the faulty multi-function switch assembly as required. Refer to Lighting and Horns/Turn Signal/Turn Signal Switch and Hazard Warning Switch Replacement for the multi-function switch service procedures. If the switches are OK, repair the wiper system and/or washer system wire harness circuits as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 7069 Windshield Washer Switch: Service and Repair REMOVAL AND INSTALLATION The wiper switch and washer switch are integral to the multi-function switch, which is installed on the left side of the steering column. If the wiper switch or the washer switch is faulty or damaged, the multi-function switch assembly must be replaced. Refer to Lighting and Horns/Turn Signal Switch and Hazard Warning Switch Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation Wiper Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch The windshield wiper and washer switches are integral to the multi-function switch assembly, which is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay interval. A paddle near the end of the switch stalk is rotated toward the instrument panel to activate the washer system. The multi-function switch also contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Horn contact and circuit. The information contained addresses only the multi-function switch windshield wiper and washer switches. For information relative to the other circuits and switches that are integral to the multi-function switch. However, the windshield wiper and washer switches cannot be repaired. If these switches or any other circuit of the multi-function switch is faulty or damaged, the entire multi-function switch assembly must be replaced. Refer to Turn Signal Switch and Hazard Warning Switch Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 7073 Wiper Switch: Testing and Inspection The wiper switch and washer switch are integral to the multi-function switch. See Wiper System and/or Washer System in the Diagnosis and Testing WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Unplug the steering column wire harness connector. Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the steering column half of the steering column wire harness connector terminals as shown in the Wiper Switch and Washer Switch Continuity chart. 3. If the wiper switch or the washer switch fails any of the continuity checks, repair the open circuit in the steering column wire harness or replace the faulty multi-function switch assembly as required. Refer to Lighting and Horns/Turn Signal/Turn Signal Switch and Hazard Warning Switch Replacement for the multi-function switch service procedures. If the switches are OK, repair the wiper system and/or washer system wire harness circuits as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 7074 Wiper Switch: Service and Repair REMOVAL AND INSTALLATION The wiper switch and washer switch are integral to the multi-function switch, which is installed on the left side of the steering column. If the wiper switch or the washer switch is faulty or damaged, the multi-function switch assembly must be replaced. Refer to Lighting and Horns/Turn Signal Switch and Hazard Warning Switch Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation Washer Fluid Level Indicator: Description and Operation SYSTEM OPERATION Low Washer Fluid Warning Lamp The low washer fluid warning lamp gives an indication when the fluid level in the washer fluid reservoir is too low. The instrument cluster circuitry lights the lamp for about two seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the instrument cluster circuitry controls the lamp based upon a hard wired input from the washer fluid level sensor. The washer fluid level sensor uses a float in the washer fluid reservoir to monitor the fluid level. The up and down action of the float opens or closes the switch within the washer fluid level sensor that provides a ground signal to the instrument cluster circuitry. If the instrument cluster circuitry senses a ground input from the washer fluid level sensor for more than about sixty seconds, it turns on the low washer fluid warning lamp and sends a chime tone request to the Central Timer Module (CTM). This helps to reduce the effects of fluid sloshing within the reservoir. This lamp also latches. Once the lamp has been turned on, it will remain on until washer fluid is added to the reservoir and the ignition switch is cycled. Refer to Washer Fluid Level Sensor in Wiper and Washer Systems/Wiper and Washer Systems for more information. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation Washer Fluid Level Switch: Description and Operation SYSTEM OPERATION Washer Fluid Level Sensor The washer fluid level sensor is mounted near the bottom of the rearward facing side of the washer reservoir. A barbed nipple on the sensor is press-fit into a rubber grommet seal installed in the mounting hole on the reservoir. When the fluid level in the washer reservoir falls below the travel limit of the float, the internal switch contacts of the sensor close. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Low Washer Fluid Warning Lamp. The washer fluid level sensor cannot be repaired. If faulty or damaged, the sensor unit must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Page 7081 Washer Fluid Level Switch: Service and Repair REMOVAL 1. Remove the washer reservoir from the engine compartment. See Washer Reservoir Replacement. NOTE: The pivoting float of the washer fluid sensor must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and held in an upright position, the pivoting float will orient itself to the horizontal position when the sensor connector is pointed straight downwards. 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry the washer fluid level sensor out of the rubber grommet seal. Care must be taken not to damage the reservoir. 3. Remove the rubber grommet seal from the reservoir and discard. 4. Reverse the removal procedures to install. Always use a new rubber grommet seal on the reservoir. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams Washer Motor Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Washer Reservoir Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 7088 Windshield Washer Pump: Description and Operation SYSTEM OPERATION The washer pump and motor are mounted near the bottom of the washer reservoir. A barbed nipple on the pump housing passes through a rubber grommet seal installed in a hole near the bottom of the reservoir. The washer pump is retained by an interference fit between the barbed pump nipple and the grommet seal, which is a light press fit. A permanently lubricated and sealed motor is coupled to a rotor-type pump. Washer fluid is gravity-fed from the reservoir to the pump. When the motor is energized, the pump pressurizes the washer fluid and forces it through the plumbing to the nozzles. The washer pump and motor unit cannot be repaired. If faulty, the entire washer pump and motor unit must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 7089 Windshield Washer Pump: Service and Repair REMOVAL 1. Remove the washer reservoir from the engine compartment. See Washer Reservoir Replacement. 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed inlet nipple of the washer pump out of the rubber grommet seal in the reservoir. Care must be taken not to damage the reservoir. 3. Remove the rubber grommet seal from the reservoir and discard. 4. Reverse the removal procedures to install. Always use a new rubber grommet seal on the reservoir. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations Washer Reservoir Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations > Page 7093 Windshield Washer Reservoir: Description and Operation SYSTEM OPERATION The windshield washer fluid reservoir is secured to the left radiator closure panel between the battery and the coolant reserve bottle in the engine compartment. The washer pump and motor unit has a barbed nipple, which is installed through a rubber grommet seal inserted in a hole near the bottom of the reservoir. The washer pump is retained by an interference fit between the barbed nipple and the grommet seal, which is a light press fit. The washer reservoir has a snap-fit filler cap with a rubber gasket. The cap hinges on and is secured to a molded-in hook formation on the reservoir body, behind the filler neck. The reservoir also has a provision for a washer fluid level sensor. The washer reservoir, grommet seals and filler cap are each available for service. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations > Page 7094 Windshield Washer Reservoir: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Washer Reservoir Remove/Install 2. Unplug the wire harness connectors from the washer pump and the washer fluid level sensor. 3. Remove the washer supply hose from the washer pump and drain the washer fluid from the reservoir into a clean container for reuse. 4. Remove the two screws that secure the top of the washer reservoir to the top of the radiator closure panel. 5. Lift the washer reservoir upwards far enough to disengage the reservoir mounting tab from the mounting slot in the lower radiator closure panel. 6. Remove the washer reservoir from the engine compartment. 7. Reverse the removal procedures to install. Tighten the mounting screws to 5.6 N.m (50 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation Windshield Washer Spray Nozzle: Description and Operation SYSTEM OPERATION Washer Nozzle And Plumbing Pressurized washer fluid is fed through a single hose, attached to a barbed nipple on the washer pump. The hose is routed to a tee fitting located in the cowl plenum area, beneath the cowl plenum cover/grille panel. Hoses from the tee fitting are routed to the lower nipple of an elbow fitting that is snapped onto the mounting plate of each wiper pivot. The upper nipple of each elbow fitting protrudes above the cowl plenum cover/grille panel near the wiper pivots. A hose attached to the upper nipple of each elbow fitting is routed through a spring-like guard to prevent the hose from kinking. The hose is then routed through a plastic trough like guard snapped to the underside of each wiper arm to a nipple on the washer nozzle. The two washer nozzles are snapped onto the wiper arms near the wiper blade and are not adjustable. Each nozzle emits four streams of washer fluid onto the windshield through the entire wipe pattern. The nozzles and hose fittings cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Page 7098 Windshield Washer Spray Nozzle: Service and Repair REMOVAL 1. Unsnap the washer nozzle from the wiper arm. 2. Disconnect the washer supply hose from the barbed washer nozzle nipple. 3. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation Windshield Washer Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch The windshield wiper and washer switches are integral to the multi-function switch assembly, which is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay interval. A paddle near the end of the switch stalk is rotated toward the instrument panel to activate the washer system. The multi-function switch also contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Horn contact and circuit. The information contained addresses only the multi-function switch windshield wiper and washer switches. For information relative to the other circuits and switches that are integral to the multi-function switch. However, the windshield wiper and washer switches cannot be repaired. If these switches or any other circuit of the multi-function switch is faulty or damaged, the entire multi-function switch assembly must be replaced. Refer to Turn Signal Switch and Hazard Warning Switch Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 7102 Windshield Washer Switch: Testing and Inspection The wiper switch and washer switch are integral to the multi-function switch. See Wiper System and/or Washer System in the Diagnosis and Testing WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Unplug the steering column wire harness connector. Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the steering column half of the steering column wire harness connector terminals as shown in the Wiper Switch and Washer Switch Continuity chart. 3. If the wiper switch or the washer switch fails any of the continuity checks, repair the open circuit in the steering column wire harness or replace the faulty multi-function switch assembly as required. Refer to Lighting and Horns/Turn Signal/Turn Signal Switch and Hazard Warning Switch Replacement for the multi-function switch service procedures. If the switches are OK, repair the wiper system and/or washer system wire harness circuits as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 7103 Windshield Washer Switch: Service and Repair REMOVAL AND INSTALLATION The wiper switch and washer switch are integral to the multi-function switch, which is installed on the left side of the steering column. If the wiper switch or the washer switch is faulty or damaged, the multi-function switch assembly must be replaced. Refer to Lighting and Horns/Turn Signal Switch and Hazard Warning Switch Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation Wiper Arm: Description and Operation SYSTEM OPERATION All Ram van/wagon models have two 47.5-centimeter (19-inch) windshield wiper blades with non-replaceable rubber elements (squeegees). These wiper blades include an anti-lift feature. The wiper blades and squeegees must be oriented correctly when installed on the wiper arms for the anti-lift feature to be effective. See Wiper Blade in the Removal and Installation for more information. Caution should be exercised to protect the rubber squeegees from any petroleum-based cleaners or contaminants, which will rapidly deteriorate the rubber. If the squeegees are damaged, worn, or contaminated, the entire wiper blade assembly must be replaced. Wiper squeegees exposed to the elements for a long time tend to lose their wiping effectiveness. Periodic cleaning of the squeegees is suggested to remove deposits of salt and road film. The wiper blades, arms, and windshield should be cleaned with a sponge or cloth and windshield washer fluid, a mild detergent, or a non-abrasive cleaner. If the squeegees continue to streak or smear, the wiper blades should be replaced. The blades are mounted to two spring-loaded wiper arms. The spring tension of the wiper arms controls the pressure applied to the blades on the glass. The windshield wiper arms are secured by an integral latch to the two wiper pivots on the cowl plenum cover/grille panel at the base of the windshield. The wiper arms and blades cannot be adjusted or repaired. If faulty or damaged, they must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation > Page 7107 Wiper Arm: Service and Repair CAUTION: The use of a screwdriver or other prying tool to remove a wiper arm may distort it. This distortion could allow the arm to come off of the pivot shaft, regardless of how carefully it is installed. Wiper Arm Remove/Install 1. Lift the wiper arm to permit the latch to be pulled out to its holding position, then release the arm. The arm will remain off the windshield with the latch in this position. 2. Slide the spring-like washer hose guard, located near the wiper pivot, up the hose toward the wiper blade. Then disconnect the washer hose at the nipple near the wiper pivot. 3. Remove the wiper arm from the pivot using a rocking motion. Wiper Arm Installation 4. Install the wiper arm and blade with the wiper motor in the Park position. See the Wiper Arm Installation illustration. 5. Mount the arms on the pivot shafts so that the distance from the lower edge of the wiper blade tip to the upper edge of the lower windshield blackout area is: 65 ± 25 millimeters (2.56 ± 0.98 inches) on the driver side - 50 ± 25 millimeters (1.97 ± 0.98 inches) on the passenger side. 6. Lift the wiper arm away from the windshield slightly to relieve the spring tension on the latch. Push the latch into the locked position and slowly release the arm until the wiper blade rests on the windshield. 7. Reinstall the washer hoses to the nipples near the wiper pivots and slide the hose guards back into position. 8. Operate the wipers with the windshield glass wet, then turn the wiper switch to the Off position. Check for the correct wiper arm positioning and readjust if required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 7121 Wiper Blade: Description and Operation SYSTEM OPERATION All Ram van/wagon models have two 47.5-centimeter (19-inch) windshield wiper blades with non-replaceable rubber elements (squeegees). These wiper blades include an anti-lift feature. The wiper blades and squeegees must be oriented correctly when installed on the wiper arms for the anti-lift feature to be effective. See Wiper Blade in the Removal and Installation for more information. Caution should be exercised to protect the rubber squeegees from any petroleum-based cleaners or contaminants, which will rapidly deteriorate the rubber. If the squeegees are damaged, worn, or contaminated, the entire wiper blade assembly must be replaced. Wiper squeegees exposed to the elements for a long time tend to lose their wiping effectiveness. Periodic cleaning of the squeegees is suggested to remove deposits of salt and road film. The wiper blades, arms, and windshield should be cleaned with a sponge or cloth and windshield washer fluid, a mild detergent, or a non-abrasive cleaner. If the squeegees continue to streak or smear, the wiper blades should be replaced. The blades are mounted to two spring-loaded wiper arms. The spring tension of the wiper arms controls the pressure applied to the blades on the glass. The windshield wiper arms are secured by an integral latch to the two wiper pivots on the cowl plenum cover/grille panel at the base of the windshield. The wiper arms and blades cannot be adjusted or repaired. If faulty or damaged, they must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 7122 Wiper Blade: Service and Repair REMOVAL AND INSTALLATION NOTE: The notched retainer end of the wiper element should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Turn the windshield wiper switch to the On position. By turning the ignition switch to the On and Off positions, cycle the wiper blades to a convenient working location on the windshield. 2. Lift the wiper arm to raise the wiper blade and element off of the windshield glass. Wiper Blade Remove/Install - Typical 3. To remove the wiper blade from the wiper arm, push the release tab under the arm tip and slide the blade away from the tip towards the pivot end of the arm. 4. To install the wiper blade on the wiper arm, slide the blade retainer into the U-shaped formation on the tip of the wiper arm until the release tab snaps into its locked position. Be certain that the notched retainer for the wiper element is oriented towards the end of the wiper blade that is nearest to the wiper pivot. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation Wiper Control Module: Description and Operation SYSTEM OPERATION Intermittent Wipe Module An intermittent wipe module is used on vehicles that are not equipped with the optional Vehicle Theft Security System (VTSS). In addition to low and high speed, the intermittent wipe system has a delay mode. Electronic circuitry within the intermittent wipe module is used to accomplish the wiper delay mode. The delay time selected by the driver has a range of from about one-half second to about fourteen seconds. The driver selects the length of the delay by placing the wiper (multi-function) switch knob in one of five different intermittent wipe detent positions. One of the detent positions sends a battery voltage signal to the intermittent wipe module, while the other four positions use resistors to provide progressively lower voltage signals to the module. If the washer knob is depressed while the wiper switch is in the Off position, the intermittent wipe module will operate the wiper motor for approximately two wipes and automatically turn off the motor. The intermittent wipe module is snap-fit onto a single blade-type mounting bracket located on the instrument panel reinforcement above the glove box opening. The intermittent wipe module cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 7126 Wiper Control Module: Testing and Inspection Intermittent Wiper Module Testing The intermittent wipe module is used on vehicles that are not equipped with the Vehicle Theft Security System (VTSS). See Wiper System in the Diagnosis and Testing before performing the following tests. If the problem being diagnosed involves only some of the intermittent wipe delay positions, see Wiper Switch and Washer Switch in the Diagnosis and Testing. If the problem being diagnosed involves all of the intermittent wipe delay positions, proceed with the following tests. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Access and unplug the intermittent wipe module wire harness connector. Check for continuity between the ground circuit cavity of the intermittent wipe module wire harness connector and a good ground. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 2. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit of the intermittent wipe module wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit to the fuse in the junction block as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the wiper motor Check for continuity between the wiper park switch sense circuit (VS) cavities of the intermittent wipe module wire harness connector and the wiper motor wire harness connector. There should be continuity. If OK, go to Step 5. If not OK, repair the open circuit as required. 4. Unplug the steering column wire harness connector. Check for continuity between the wiper park switch sense circuit (V7) cavities of the intermittent wipe module wire harness connector and the instrument panel half of the steering column wire harness connector. There should be continuity. If OK, go to Step 6. If not OK, repair the open circuit as required. 5. Check for continuity between the wiper switch mode signal circuit cavities of the intermittent wipe module wire harness connector and the instrument panel half of the steering column wire harness connector. There should be continuity. If OK, go to Step 7. If not OK, repair the open circuit as required. 6. Check for continuity between the wiper switch delay output circuit cavities of the intermittent wipe module wire harness connector and the instrument panel half of the steering column wire harness connector. There should be continuity. If OK, go to Step 8. If not OK, repair the open circuit as required. 7. Test the multi-function switch continuity. See Wiper Switch and Washer Switch in the Diagnosis and Testing. If the switch tests OK, replace the faulty intermittent wipe module. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 7127 Wiper Control Module: Service and Repair Intermittent Wipe Module Replacement REMOVAL An intermittent wipe module is used on vehicles that are not equipped with the optional Vehicle Theft Security System (VTSS). See Intermittent Wipe Module and Central Timer Module in the Description and Operation for more information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Roll down the glove box from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Glove Box - Roll Down Replacement. Instermittent Wiper Module Remove/Install 3. Reach through and above the glove box opening to access the intermittent wipe module. Push the module towards the front of the vehicle to disengage the snap-fit slot on the intermittent wipe module from the slide tab of the mounting bracket on the instrument panel armature. 4. Lower the intermittent wipe module into the instrument panel glove box opening far enough to access and unplug the wire harness connector. 5. Reverse the removal procedures to install. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation Wiper Motor: Description and Operation SYSTEM OPERATION The two-speed permanent magnet wiper motor has an integral transmission and park switch. The motor has a rubber-isolated mounting bracket that is secured with screws to a reinforcement with weld nuts on the engine side of the cowl plenum panel. The wiper motor output shaft and crank arm passes through a hole in the cowl plenum panel into the cowl plenum area. Wiper speed is controlled by current flow to the proper set of brushes. The wiper motor completes its wipe cycle when the windshield wiper switch on the end of the multi-function switch stalk is turned to the Off position, and parks the blades in the lowest portion of the wipe pattern. The windshield wiper motor cannot be repaired. If faulty or damaged, the entire wiper motor assembly must be replaced. The wiper linkage and pivots, and the reinforcement are available for service. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation > Page 7131 Wiper Motor: Service and Repair REMOVAL 1. Remove the drive link from the wiper motor crank arm. See Wiper Linkage and Pivot Replacement for the procedures. 2. Disconnect and isolate the battery negative cable. Wiper Motor Remove/Install 3. Unplug the wire harness connector from the wiper motor. 4. Remove the three screws that secure the wiper motor to the cowl plenum panel reinforcement. 5. Remove the wiper motor from the cowl plenum panel. 6. Reverse the removal procedures to install. Tighten the mounting screws to 11.8 N.m (105 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description and Operation Wiper Motor Linkage: Description and Operation SYSTEM OPERATION The wiper linkage and pivot module is secured with screws to the cowl top panel beneath the cowl plenum cover/grille panel. The wiper motor is secured with screws on the engine compartment side of the cowl plenum panel. The wiper motor output shaft and crank arm are installed through a hole in the cowl plenum panel into the cowl plenum area, where they are connected to the wiper linkage. The two wiper pivot crank arms and the wiper motor crank arm each have ball studs on their ends. The ball stud on the driver side pivot crank arm is longer than the other two ball studs. A connecting link with a plastic socket-type bushing in the passenger side end, and a plastic sleeve-type bushing in the driver side end, is fit over the pivot crank arm ball studs to join the two pivots. The wiper drive link has a plastic socket-type bushing on each end. One end of the drive link is snap-fit over the exposed end of the longer driver side pivot ball stud, while the other end is snap-fit over the ball stud on the wiper motor crank arm. The wiper linkage, pivots, and bushings are only serviced as a complete unit. If any part of this assembly is faulty, the entire wiper linkage unit must be replaced. The wiper motor is serviced separately. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description and Operation > Page 7135 Wiper Motor Linkage: Service and Repair 1. Remove the wiper arms from the wiper pivots. See Wiper Arm Replacement. Cowl Plenum Cover/grille Panel Remove/Install 2. Open the hood and remove the screws that secure the cowl plenum cover/grille panel to the cowl top panel. 3. Using a trim stick or another suitable wide flat-bladed tool, gently pry up on each end of the cowl plenum cover/grille panel to release the snap clip retainer that secures it to the cowl top panel. 4. Remove the cowl plenum cover/grille panel from the cowl top. CAUTION: Do not apply pressure to, or pry on, the plastic drive link bushing. When removing or installing the drive link to the crank arm, apply pressure to, or pry on, only the metal portions of the drive link around the bushing. Otherwise, the bushing may be damaged and the linkage rendered unserviceable. Wiper Linkage And Remove/Install 5. Remove the wiper linkage drive link from the wiper motor crank arm by prying the drive link bushing off of the crank arm ball stud. Use two suitably sized screwdrivers, one on each side of the ball stud, and pry between the crank arm and the metal portion of the drive link. 6. Gently pry the two washer hose elbow fittings from the pivot mounting flanges. 7. Remove the four screws that secure the pivot mounting flanges to the cowl top panel. 8. Working through the cowl top panel access holes, remove the linkage and pivot assembly from the cowl plenum as a unit. CAUTION: Do not apply pressure to, or pry on, the plastic drive link bushing. When removing or installing the drive link to the crank arm, apply pressure to, or pry on, only the metal portions of the drive link around the bushing. Otherwise, the bushing may be damaged and the linkage rendered unserviceable. 9. Reverse the removal procedures to install. Place a short 19 millimeter or 3/4 inch socket over the capped side of the drive link bushing as a protective sleeve. Then use channel-lock pliers to reinstall the drive link bushing onto the crank arm ball stud. Apply pressure with the pliers to the crank arm and the socket. Do not apply pressure directly to the plastic bushing. Tighten the pivot mounting screws to 11 N.m (95 in. lbs.). Tighten the cowl plenum cover/ grille panel mounting screws to 2 N.m (17 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and Operation Wiper Pivot: Description and Operation SYSTEM OPERATION The wiper linkage and pivot module is secured with screws to the cowl top panel beneath the cowl plenum cover/grille panel. The wiper motor is secured with screws on the engine compartment side of the cowl plenum panel. The wiper motor output shaft and crank arm are installed through a hole in the cowl plenum panel into the cowl plenum area, where they are connected to the wiper linkage. The two wiper pivot crank arms and the wiper motor crank arm each have ball studs on their ends. The ball stud on the driver side pivot crank arm is longer than the other two ball studs. A connecting link with a plastic socket-type bushing in the passenger side end, and a plastic sleeve-type bushing in the driver side end, is fit over the pivot crank arm ball studs to join the two pivots. The wiper drive link has a plastic socket-type bushing on each end. One end of the drive link is snap-fit over the exposed end of the longer driver side pivot ball stud, while the other end is snap-fit over the ball stud on the wiper motor crank arm. The wiper linkage, pivots, and bushings are only serviced as a complete unit. If any part of this assembly is faulty, the entire wiper linkage unit must be replaced. The wiper motor is serviced separately. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and Operation > Page 7139 Wiper Pivot: Service and Repair 1. Remove the wiper arms from the wiper pivots. See Wiper Arm Replacement. Cowl Plenum Cover/grille Panel Remove/Install 2. Open the hood and remove the screws that secure the cowl plenum cover/grille panel to the cowl top panel. 3. Using a trim stick or another suitable wide flat-bladed tool, gently pry up on each end of the cowl plenum cover/grille panel to release the snap clip retainer that secures it to the cowl top panel. 4. Remove the cowl plenum cover/grille panel from the cowl top. CAUTION: Do not apply pressure to, or pry on, the plastic drive link bushing. When removing or installing the drive link to the crank arm, apply pressure to, or pry on, only the metal portions of the drive link around the bushing. Otherwise, the bushing may be damaged and the linkage rendered unserviceable. Wiper Linkage And Remove/Install 5. Remove the wiper linkage drive link from the wiper motor crank arm by prying the drive link bushing off of the crank arm ball stud. Use two suitably sized screwdrivers, one on each side of the ball stud, and pry between the crank arm and the metal portion of the drive link. 6. Gently pry the two washer hose elbow fittings from the pivot mounting flanges. 7. Remove the four screws that secure the pivot mounting flanges to the cowl top panel. 8. Working through the cowl top panel access holes, remove the linkage and pivot assembly from the cowl plenum as a unit. CAUTION: Do not apply pressure to, or pry on, the plastic drive link bushing. When removing or installing the drive link to the crank arm, apply pressure to, or pry on, only the metal portions of the drive link around the bushing. Otherwise, the bushing may be damaged and the linkage rendered unserviceable. 9. Reverse the removal procedures to install. Place a short 19 millimeter or 3/4 inch socket over the capped side of the drive link bushing as a protective sleeve. Then use channel-lock pliers to reinstall the drive link bushing onto the crank arm ball stud. Apply pressure with the pliers to the crank arm and the socket. Do not apply pressure directly to the plastic bushing. Tighten the pivot mounting screws to 11 N.m (95 in. lbs.). Tighten the cowl plenum cover/ grille panel mounting screws to 2 N.m (17 in. lbs.). Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams Wiper Relay: Diagrams Intermittent Wiper Relay Connector Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 7143 Wiper Relay: Description and Operation SYSTEM OPERATION An intermittent wipe relay is used on models that are equipped with the optional Vehicle Theft Security System (VTSS). The intermittent wipe relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The intermittent wipe relay is a electromechanical device that switches battery current to the windshield wiper motor when the relay coil is grounded by the Central Timer Module (CTM) in response to inputs from the windshield wiper (multi-function) switch. See Intermittent Wipe Relay in the Diagnosis. The intermittent wipe relay is located in a connector that is taped back to the instrument panel wire harness above the inboard side of the glove box opening. The intermittent wipe relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 7144 Wiper Relay: Testing and Inspection The intermittent wipe relay is used on vehicles that are equipped with the Vehicle Theft Security System (VTSS). See Wiper System in the Diagnosis and Testing before performing the following tests. If the problem being diagnosed involves only some of the intermittent wipe delay positions, see Wiper Switch and Washer Switch in the Diagnosis and Testing. If the problem being diagnosed involves all of the intermittent wipe delay positions, proceed with the following tests. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Test Instrument Wipe Relay The intermittent wipe relay is located in a connector that is taped back to the instrument panel wire harness above the inboard side of the glove box opening in the passenger compartment. Remove the intermittent wipe relay from its wire harness connector as described Replacement to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the wiper (multi-function) switch. There should be continuity between the cavity for relay terminal 30 and the two washer switch output (V11A and V11B) circuit cavities in the instrument panel half of the steering column wire harness connector at all times. If OK, go to Step 3. If not OK, repair the open circuit(s) to the wiper (mufti-function) switch as a required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position. There should be continuity between the cavity for relay terminal 87A and the wiper park switch sense circuit cavities of the wiper motor wire harness connector and the 14-way Central Timer Module (CTM) wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit(s) to the wiper motor and CTM as required. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. There should be battery voltage at the cavity for relay terminal 87 with the ignition switch in the On or Accessory positions. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the junction block as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On or Accessory positions. If OK, go to Step 6. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded by the CTM to energize the relay and cycle the wiper motor. a Check for continuity between the cavity for relay terminal 85 and the intermittent wiper relay control circuit cavity of the 14-way CTM wire harness connector. There should be continuity If OK, use a DRB scan tool and the proper Diagnostic Procedures for diagnosis of the CTM. If not OK, repair the open circuit to the CTM as required. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 7145 Wiper Relay: Service and Repair Intermittent Wipe Relay Replacement An intermittent wipe relay is used on vehicles that are equipped with the optional Vehicle Theft Security System (VTSS). See Intermittent Wipe Relay and Central Timer Module in the Description and Operation for more information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Roll down the glove box from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Glove Box - Roll Down Replacement. Intermittent Wipe Relay Remove/Install 3. Reach through and above the inboard side of the glove box opening to access the intermittent wipe relay. Remove the tape that secures the relay and its connector to the wire harness near the instrument panel armature. 4. Lower the intermittent wipe relay into the instrument panel glove box opening far enough to access and unplug the relay from its wire harness connector. 5. Install the intermittent wipe relay by aligning the relay terminals with the cavities in the wire harness connector and pushing the relay firmly into place. 6. Tape the intermittent wipe relay and its wire harness connector back to the wire harness. 7. Reinstall the glove box in the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Glove Box - Roll Down Replacement. 8. Connect the battery negative cable. 9. Test the relay operation. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation Wiper Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch The windshield wiper and washer switches are integral to the multi-function switch assembly, which is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay interval. A paddle near the end of the switch stalk is rotated toward the instrument panel to activate the washer system. The multi-function switch also contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Horn contact and circuit. The information contained addresses only the multi-function switch windshield wiper and washer switches. For information relative to the other circuits and switches that are integral to the multi-function switch. However, the windshield wiper and washer switches cannot be repaired. If these switches or any other circuit of the multi-function switch is faulty or damaged, the entire multi-function switch assembly must be replaced. Refer to Turn Signal Switch and Hazard Warning Switch Replacement. Dodge Ram 3500 Van Workshop Manual (V8-5.9L VIN Z LDC (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 7149 Wiper Switch: Testing and Inspection The wiper switch and washer switch are integral to the multi-function switch. See Wiper System and/or Washer System in the Diagnosis and Testing WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Unplug the steering column wire harness connector. Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the steering column half of the steering column wire harness connector terminals as shown in the Wiper Switch and Washer Switch Continuity chart. 3. If the wiper switch or the washer switch fails any of the continuity checks, repair the open circuit in the steering column wire harness or replace the faulty multi-function switch assembly as required. Refer to Lighting and Horns/Turn Signal/Turn Signal Switch and Hazard Warning Switch Replacement for the multi-function switch service procedures. If the switches are OK, repair the wiper system and/or washer system wire harness circuits as required.